Battery system with heat exchanger

ABSTRACT

A battery module includes a plurality of electrochemical cells arranged in a first row and a second row offset from the first row. The battery module also includes a heat exchanger configured to allow a fluid to flow through the heat exchanger. The heat exchanger is disposed between the first and second rows of cells and has a shape that is complementary to the cells in the first and second rows of cells so that an external surface of the heat exchanger contacts a portion of each of the plurality of electrochemical cells. The heat exchanger is configured to route the fluid between an inlet and an outlet such that a path of the fluid flow includes a plurality of adjacent fluid flow segments.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of International Patent ApplicationNo. PCT/US2009/064032, filed Nov. 11, 2009, which claims the benefit ofand priority to U.S. Provisional Patent Application No. 61/114,009,filed Nov. 12, 2008, U.S. Provisional Patent Application No. 61/143,707,filed Jan. 9, 2009, and U.S. Provisional Patent Application No.61/169,649, filed Apr. 15, 2009. The entire disclosures of InternationalPatent Application No. PCT/US2009/064032, U.S. Provisional PatentApplication No. 61/114,009, U.S. Provisional Patent Application No.61/143,707, and U.S. Provisional Patent Application No. 61/169,649 areincorporated herein by reference in their entireties.

BACKGROUND

The present application relates generally to the field of batteries andbattery systems. More specifically, the present application relates tobatteries and battery systems that may be used in vehicle applicationsto provide at least a portion of the motive power for the vehicle.

Vehicles using electric power for all or a portion of their motive power(e.g., electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-inhybrid electric vehicles (PHEVs), and the like, collectively referred toas “electric vehicles”) may provide a number of advantages as comparedto more traditional gas-powered vehicles using internal combustionengines. For example, electric vehicles may produce fewer undesirableemission products and may exhibit greater fuel efficiency as compared tovehicles using internal combustion engines (and, in some cases, suchvehicles may eliminate the use of gasoline entirely, as is the case ofcertain types of PHEVs).

As electric vehicle technology continues to evolve, there is a need toprovide improved power sources (e.g., battery systems or modules) forsuch vehicles. For example, it is desirable to increase the distancethat such vehicles may travel without the need to recharge thebatteries. It is also desirable to improve the performance of suchbatteries and to reduce the cost associated with the battery systems.

One area of improvement that continues to develop is in the area ofbattery chemistry. Early electric vehicle systems employednickel-metal-hydride (NiMH) batteries as a propulsion source. Over time,different additives and modifications have improved the performance,reliability, and utility of NiMH batteries.

More recently, manufacturers have begun to develop lithium-ion batteriesthat may be used in electric vehicles. There are several advantagesassociated with using lithium-ion batteries for vehicle applications.For example, lithium-ion batteries have a higher charge density andspecific power than NiMH batteries. Stated another way, lithium-ionbatteries may be smaller than NiMH batteries while storing the sameamount of charge, which may allow for weight and space savings in theelectric vehicle (or, alternatively, this feature may allowmanufacturers to provide a greater amount of power for the vehiclewithout increasing the weight of the vehicle or the space taken up bythe battery system).

It is generally known that lithium-ion batteries perform differentlythan NiMH batteries and may present design and engineering challengesthat differ from those presented with NiMH battery technology. Forexample, lithium-ion batteries may be more susceptible to variations inbattery temperature than comparable NiMH batteries, and thus systems maybe used to regulate the temperatures of the lithium-ion batteries duringvehicle operation. The manufacture of lithium-ion batteries alsopresents challenges unique to this battery chemistry, and new methodsand systems are being developed to address such challenges.

It would be desirable to provide an improved battery module and/orsystem for use in electric vehicles that addresses one or morechallenges associated with NiMH and/or lithium-ion battery systems usedin such vehicles. It also be desirable to provide a battery moduleand/or system that includes any one or more of the advantageous featuresthat will be apparent from a review of the present disclosure.

SUMMARY

According to an exemplary embodiment, a battery module includes aplurality of electrochemical cells arranged in a first row and a secondrow offset from the first row. The battery module also includes a heatexchanger configured to allow a fluid to flow through the heatexchanger. The heat exchanger is disposed between the first and secondrows of cells and has a shape that is complementary to the cells in thefirst and second rows of cells so that an external surface of the heatexchanger contacts a portion of each of the plurality of electrochemicalcells. The heat exchanger is configured to route the fluid between aninlet and an outlet such that a path of the fluid flow includes aplurality of adjacent fluid flow segments.

According to another exemplary embodiment, a battery module includes aheat exchanger provided between a first row of electrochemical cells anda second row of electrochemical cells arranged offset from the first rowof cells. The heat exchanger includes an external surface in contactwith at least a portion of each of the electrochemical cells. The heatexchanger is configured to allow a fluid to flow therethrough between aninlet and an outlet such that a path of the fluid flow includes aplurality of adjacent fluid flow segments.

According to another exemplary embodiment, a battery system includes aplurality of battery modules. Each battery module includes a pluralityof electrochemical cells arranged in a first row and a second row offsetfrom the first row. The battery module also includes a heat exchangerconfigured to allow a fluid to flow through the heat exchanger. The heatexchanger is disposed between the first and second rows of cells and hasa shape that is complementary to the cells in the first and second rowsof cells so that an external surface of the heat exchanger contacts aportion of each of the plurality of electrochemical cells. The heatexchanger is configured to route the fluid between an inlet and anoutlet such that a path of the fluid flow includes a plurality ofadjacent fluid flow segments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle including a battery moduleaccording to an exemplary embodiment.

FIG. 2 is a cutaway schematic view of a vehicle including a batterymodule according to another exemplary embodiment.

FIG. 3 is a top view of a battery system including a plurality ofbattery modules according to another exemplary embodiment.

FIG. 4A is a perspective view of a battery module according to anexemplary embodiment.

FIG. 4B is an end view of the battery module shown in FIG. 4A.

FIG. 4C is a side view of the battery module shown in FIG. 4A.

FIG. 4D is a top view of the battery module shown in FIG. 4A.

FIG. 5A is a perspective view of a battery module according to anotherexemplary embodiment.

FIG. 5B is an end view of the battery module shown in FIG. 5A.

FIG. 5C is a side view of the battery module shown in FIG. 5A.

FIG. 5D is a cut-away top view of the battery module shown in FIG. 5Ashowing a plurality of electrochemical cells according to an exemplaryembodiment

FIG. 6 is a partial exploded view of the battery module shown in FIG.5A.

FIG. 7A is a perspective view of a battery module according to anotherexemplary embodiment.

FIG. 7B is an end view of the battery module shown in FIG. 7A.

FIG. 7C is a side view of the battery module shown in FIG. 7A.

FIG. 7D is a top view of the battery module as shown in FIG. 7A.

FIG. 8A is a perspective view of a battery module according to anotherexemplary embodiment.

FIG. 8B is an end view of the battery module shown in FIG. 8A.

FIG. 8C is a side view of the battery module shown in FIG. 8A.

FIG. 8D is a cut-away top view of the battery module shown in FIG. 8Ashowing a plurality of electrochemical cells according to an exemplaryembodiment.

FIG. 9 is a partial exploded view of the battery module shown in FIG.8A.

FIGS. 10A and 10B are side-by-side comparisons of the battery moduleshown in FIGS. 4A and 7A according to an exemplary embodiment.

FIG. 11A is a perspective view of a cover for a battery module accordingto an exemplary embodiment.

FIG. 11B is a perspective view of a cover for a battery module accordingto another exemplary embodiment.

FIG. 12 is a perspective view of a cell supervisory controller (CSC)according to an exemplary embodiment.

FIG. 13 is a perspective view of a bus bar assembly according to anexemplary embodiment.

FIGS. 14A and 14B are perspective views of a housing for use with abattery module according to an exemplary embodiment.

FIG. 15A is a perspective view of a heat exchanger for use in a batterymodule according an exemplary embodiment.

FIG. 15B is a side view of the heat exchanger shown in FIG. 15A.

FIG. 15C is an end view of the heat exchanger shown in FIG. 15A.

FIG. 15D is a top view of the heat exchanger shown in FIG. 15A.

FIG. 15E is a top view of the heat exchanger shown in FIG. 15A shownprovided between two rows of electrochemical cells according to anexemplary embodiment.

FIG. 16 is a partial exploded view of an inlay being provided in a trayfor use with a battery module according to an exemplary embodiment.

FIG. 17 is a perspective view of a battery module according to anotherexemplary embodiment.

FIG. 18 is a perspective view of a bus bar assembly for use with abattery module according to another exemplary embodiment.

FIG. 19 is a perspective view of a trace board and CSC assembly for usewith a battery module according to another exemplary embodiment.

FIG. 20 is a perspective view of a heat exchanger for use with a batterymodule according to another exemplary embodiment.

FIG. 21 is a perspective view of a housing for a battery moduleaccording to an exemplary embodiment.

FIG. 22 is a perspective view of a heat exchanger inserted into thehousing shown in FIG. 21 according to an exemplary embodiment.

FIGS. 22A and 22B are partial perspective views of the placement of theinlet/outlet of the heat exchanger shown in FIG. 22 according to anexemplary embodiment.

FIG. 23 is a side view of the heat exchanger shown in FIG. 22 accordingto an exemplary embodiment.

FIG. 24 is a top view of the heat exchanger shown in FIG. 23.

FIG. 25 is an end view of the heat exchanger shown in FIG. 23.

FIG. 26 is a perspective view of a plurality of cells being insertedinto the housing shown in FIG. 22 according to an exemplary embodiment.

FIGS. 26A and 26B show the proper assembly of the electrochemical cellsinto the housing shown in FIG. 26.

FIGS. 27A and 27B are perspective views showing the placement oftemperature sensors in the housing shown in FIG. 26 according to variousexemplary embodiments.

FIG. 28 is a perspective view of a tray for a battery module having aplurality of inlays being provided therein according to an exemplaryembodiment.

FIG. 29 is a perspective view showing the tray shown in FIG. 28 beingassembled to the housing as shown in FIG. 26 according to an exemplaryembodiment.

FIG. 29A is a detailed perspective view showing a fastener and a nutbeing used to couple the tray to the housing as shown in FIG. 29according to an exemplary embodiment.

FIGS. 30 and 30A are perspective views showing a pair of connectiveelements being provided into the housing according to an exemplaryembodiment.

FIG. 31 is a perspective view of a bus bar assembly being provided tothe housing shown in FIG. 30 according to an exemplary embodiment.

FIG. 31A is a partial exploded view of a temperature sensor beingassembled into the housing shown in FIG. 31 according to an exemplaryembodiment.

FIG. 32 is a perspective view of a traceboard being provided to the busbar assembly shown in FIG. 31 according to an exemplary embodiment.

FIGS. 33 and 33A are perspective views showing a plurality of flexiblecontacts being coupled to bus bars of the bus bar assembly shown in FIG.31 according to an exemplary embodiment.

FIG. 34 is a perspective view showing a CSC being provided to thetraceboard as shown in FIG. 33 according to an exemplary embodiment.

FIGS. 35 and 35A are perspective views of a cover being assembled to thehousing as shown in FIG. 34 according to an exemplary embodiment.

FIGS. 36 and 37 show an alternative location or placement of atemperature sensor in a battery module according to another exemplaryembodiment.

FIGS. 38A and 38B are perspective views of a battery system including aplurality of battery modules according to another exemplary embodiment.

FIG. 39 is a perspective view of a portion of a vehicle configured toreceive a battery system according to an exemplary embodiment.

FIGS. 40A-40C are partial perspective views of a battery system havingan inlet manifold and an outlet manifold according to an exemplaryembodiment.

FIG. 41A is a perspective view of a service disconnect shown in aconnected state according to an exemplary embodiment.

FIG. 41B is a perspective view of the service disconnect shown in FIG.40A shown in a disconnected state according to an exemplary embodiment.

FIG. 42 is a partial exploded view of a battery system having aplurality of battery modules according to another exemplary embodiment.

FIG. 43 is a bottom perspective view of the battery system shown in FIG.42 according to an exemplary embodiment.

FIG. 44 is a partial cut-away perspective view of the battery systemshown in FIG. 42 according to an exemplary embodiment.

FIG. 45 is a partial exploded view of the battery system shown in FIG.42 according to an exemplary embodiment.

FIG. 46 is a partial perspective view of a battery system according toanother exemplary embodiment.

FIG. 47 is a partial perspective view of the battery system shown inFIG. 46 having an inlet manifold and an outlet manifold according to anexemplary embodiment.

FIG. 48 is a perspective view of a battery module according to anotherexemplary embodiment.

FIG. 49 is a partial exploded view of the battery module shown in FIG.48 according to an exemplary embodiment.

FIG. 50 is a partial perspective view of a plurality of inlays beingprovided in a tray for the battery module shown in FIG. 48 according toan exemplary embodiment.

FIG. 51 is a partial exploded view of the battery module shown in FIG.48 according to an exemplary embodiment.

FIGS. 52-53 are perspective views of the tray shown coupled to thehousing according to an exemplary embodiment.

FIG. 54A is a side view of a heat exchanger for use in the batterymodule shown in FIG. 48 according to an exemplary embodiment.

FIG. 54B is a top view of the heat exchanger shown in FIG. 54A.

FIG. 54C is an end view of the heat exchanger shown in FIG. 54A.

FIGS. 55-57 are partial perspective views of the battery module shown inFIG. 48 including a bracket configured to hold a temperature sensoraccording to an exemplary embodiment.

FIG. 58A is a perspective view of a bracket configured to hold atemperature sensor according to an exemplary embodiment.

FIG. 58B is an end view of the bracket shown in FIG. 58A.

FIG. 58C is a side view of the bracket shown in FIG. 58A.

FIG. 58D is a cross-sectional view of the bracket shown in FIG. 58Ataken alone line 58D-58D in FIG. 58C.

FIG. 59 is a partial perspective view of the battery module shown inFIG. 48 according to an exemplary embodiment.

FIGS. 60-62 are perspective views of a battery system according toanother exemplary embodiment.

FIG. 63 is a side view of the battery system shown in FIGS. 60-62according to an exemplary embodiment.

FIG. 64A is a perspective view of the battery system shown in FIGS.60-62 having opaque covers according to an exemplary embodiment.

FIG. 64B is a partial cut-away perspective view of the battery systemshown in FIG. 64A according to an exemplary embodiment.

FIG. 64C is a perspective view of the battery system shown in FIG. 64Bhaving the external covers and housing removed according to an exemplaryembodiment.

FIG. 64D is a front view of a service disconnect switch for the batterysystem shown in FIGS. 64A and 64B according to an exemplary embodiment.

FIG. 65 is a partial perspective view of a battery system according toanother exemplary embodiment.

FIG. 66 is a partial perspective view of the battery system shown inFIG. 65 having the external cover or housing removed according to anexemplary embodiment.

FIG. 67 is a front perspective view of the battery system shown in FIG.66 according to an exemplary embodiment.

FIG. 68 is a partial exploded view of the battery system shown in FIG.65 according to an exemplary embodiment.

FIGS. 69A-69C are various side-by-side comparison views of a stampedcover/terminal assembly and a conventional lid/terminal assemblyaccording to an exemplary embodiment.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of a vehicle 10 in the form of anautomobile (e.g., a car) having a battery system 20 for providing all ora portion of the motive power for the vehicle 10. Such a vehicle 10 canbe an electric vehicle (EV), a hybrid electric vehicle (HEV), a plug-inhybrid electric vehicle (PHEV), or other type of vehicle using electricpower for propulsion (collectively referred to as “electric vehicles”).

Although the vehicle 10 is illustrated as a car in FIG. 1, the type ofvehicle may differ according to other exemplary embodiments, all ofwhich are intended to fall within the scope of the present disclosure.For example, the vehicle 10 may be a truck, bus, industrial vehicle,motorcycle, recreational vehicle, boat, or any other type of vehiclethat may benefit from the use of electric power for all or a portion ofits propulsion power.

Although the battery system 20 is illustrated in FIG. 1 as beingpositioned in the trunk or rear of the vehicle, according to otherexemplary embodiments, the location of the battery system 20 may differ.For example, the position of the battery system 20 may be selected basedon the available space within a vehicle, the desired weight balance ofthe vehicle, the location of other components used with the batterysystem 20 (e.g., battery management systems, vents or cooling devices,etc.), and a variety of other considerations.

FIG. 2 illustrates a cutaway schematic view of a vehicle 11 provided inthe form of an HEV according to an exemplary embodiment. A batterysystem 21 is provided toward the rear of the vehicle 11 proximate a fueltank 12 (the battery system 21 may be provided immediately adjacent thefuel tank 12 or may be provided in a separate compartment in the rear ofthe vehicle 11 (e.g., a trunk) or may be provided elsewhere in thevehicle 11). An internal combustion engine 14 is provided for times whenthe vehicle 11 utilizes gasoline power to propel the vehicle 11. Anelectric motor 16, a power split device 17, and a generator 18 are alsoprovided as part of the vehicle drive system.

Such a vehicle 11 may be powered or driven by just the battery system21, by just the engine 14, or by both the battery system 21 and theengine 14. It should be noted that other types of vehicles andconfigurations for the vehicle drive system may be used according toother exemplary embodiments, and that the schematic illustration of FIG.2 should not be considered to limit the scope of the subject matterdescribed in the present application.

According to various exemplary embodiments, the size, shape, andlocation of the battery system 21, the type of vehicle 11, the type ofvehicle technology (e.g., EV, HEV, PHEV, etc.), and the batterychemistry, among other features, may differ from those shown ordescribed.

According to an exemplary embodiment, the battery system 21 includes aplurality of electrochemical batteries or cells. The battery system 21may also include features or components for connecting theelectrochemical cells to each other and/or to other components of thevehicle electrical system, and also for regulating the electrochemicalcells and other features of the battery system 21. For example, thebattery system 21 may include features that are responsible formonitoring and controlling the electrical performance of the batterysystem 21, managing the thermal behavior of the battery system 21,containment and/or routing of effluent (e.g., gases that may be ventedfrom an electrochemical cell through a vent), and other aspects of thebattery system 21.

Referring to FIG. 3, a top view of a battery system 22 is shownaccording to an exemplary embodiment. The battery system 22 includes aplurality of battery modules 24 and a battery disconnect unit 26 thatincludes an electronic control unit shown as a battery management system(BMS) 28. The BMS 28 monitors and regulates the current, voltage, and/ortemperature of the electrochemical cells (not shown) in the batterymodules.

Although illustrated in FIG. 3 as having a particular number of batterymodules 24 (i.e., nine battery modules), it should be noted thataccording to other exemplary embodiments, a different number and/orarrangement of battery modules 24 may be included in the battery system22 depending on any of a variety of considerations (e.g., the desiredpower for the battery system 22, the available space within which thebattery system 22 must fit, etc.). The design and construction of thebattery modules 24 allow for modular assembly (e.g., the modules may bequickly and efficiently mechanically, electrically, and/or thermallycoupled to one another or with other components of the battery system22).

Referring now to FIGS. 4A-6, various views of battery packs or batterymodules 24, 124 are shown according to various exemplary embodiments.The battery modules 24, 124 include a plurality of electrochemical cellsor batteries (e.g., lithium-ion cells, nickel-metal-hydride cells,lithium polymer cells, etc., or other types of electrochemical cells nowknown or hereafter developed). According to an exemplary embodiment, theelectrochemical cells (such as, e.g., electrochemical cells 130 as shownin FIG. 6) are generally cylindrical lithium-ion cells configured tostore an electrical charge. According to other exemplary embodiments,the cells could have other physical configurations (e.g., oval,prismatic, polygonal, etc.). The capacity, size, design, and otherfeatures of the cells may also differ from those shown according toother exemplary embodiments.

Although illustrated in FIGS. 4A-6 as having a particular number ofelectrochemical cells (i.e., two rows of six electrochemical cellsarranged side-by-side for a total of twelve electrochemical cells), itshould be noted that according to other exemplary embodiments, adifferent number and/or arrangement of electrochemical cells may be useddepending on any of a variety of considerations (e.g., the desired powerfor the battery system, the available space within which the batterymodule must fit, etc.).

According to an exemplary embodiment, the two rows of cells 130 areoffset from one another (e.g., by an angle “A” as shown in FIG. 5D) toallow for an efficient use of space within the battery modules 24, 124.According to one exemplary embodiment, the two rows of cells 130 areoffset from one another at an angle A between approximately 60 degreesand 80 degrees, although this angle A may be greater or lesser accordingto other embodiments (e.g., the cells 130 may be offset from one anotherat an angle A of 45 degrees). According to a particular exemplaryembodiment, the two rows of cells 130 are offset from one another at anangle A of approximately 70 degrees.

Referring to FIG. 6, a partial exploded view of the battery module 124is shown according to an exemplary embodiment. The battery module 124includes a plurality of the electrochemical cells 130 providedside-by-side in two rows. A heat exchanger 140 is provided in betweenthe two rows of cells 130 and is configured to provide cooling and/orheating to the cells 130. A body or housing 150 is provided around thecells 130 to at least partially or substantially enclose the cells 130(as illustrated, the walls of the housing have an undulating or wavyshape that is complementary to the shape of the cylindrical cells sothat the housing can be in contact with external surfaces of the cells).A member or bottom shown as a tray 160 is provided below the cells 130and attaches to the lower portion of the body to form a base. Aplurality of members or elements provided in the form of inlays 162 areprovided in the tray 160 and are situated below the individual cells130.

According to an exemplary embodiment, a bus bar assembly 170 is providedon top of the housing 150 and is configured to electrically connect oneor more of the cells 130 to one another or to other components of thebattery system 22. A cell supervisory controller (CSC) 182 and atraceboard 180 are provided above the bus bar assembly 170. A cover 190is provided above the CSC 182, traceboard 180, and bus bar assembly 170and attaches to an upper portion of the housing 150. The cover 190 isconfigured to substantially enclose the CSC 182, traceboard 180, and busbar assembly 170.

Each of the electrochemical cells 130 includes a plurality of terminals(e.g., two terminals). According to an exemplary embodiment, theelectrochemical cells 130 include one positive terminal 132 and onenegative terminal 134 at a first end of the cell 130 (e.g., as shown inFIG. 6). The electrochemical cells 130 also include a vent 136 at asecond end of the cell 130 opposite of the first end. The vent 136 isconfigured to break away (i.e., deploy) from the cell 130 once theinternal pressure of the cell 130 reaches a predetermined level. Whenthe vent 136 is deployed (i.e., broken away from the cell), gases and/oreffluent may be released from the cell 130. According to an exemplaryembodiment, the vent 136 is a circular vent disk located at the bottomof the cell 130. According to other exemplary embodiments, the cells 130may have different terminal and/or vent configurations (e.g., thepositive terminal may be located on one end of the cell 130 and thenegative terminal may be located on the opposite end of the cell 130).

Referring now to FIGS. 7A-9, battery modules 224, 324 are shownaccording to various exemplary embodiments. The battery modules 224, 324shown in FIGS. 7A-9 are similar to the battery modules shown in FIGS.4A-6, with one difference being that the battery modules 224, 324 shownin FIGS. 7A-9 do not include a separate traceboard (i.e., the traceboardis included in the CSC). By including the traceboard in the design ofthe CSC, the height of the battery modules 224, 324 is less than that ofthe battery modules shown in FIGS. 4A-6 (as shown, for example, in FIGS.10A and 10B).

Referring to FIGS. 11A and 11B, a cover 190, 390 for the battery module124, 324 is shown according to a first exemplary embodiment and a secondexemplary embodiment. The external shape of the cover 190, 390 isconfigured to match the external shape of the housing 150, 350. Thecover 190, 390 may be provided with features to allow the cover 190, 390to be coupled to the housing 150, 350 (e.g., snap-fit features). Thecover 190, 390 may be made of a polymeric material or other suitablematerial (e.g., an electrically insulative material).

The main difference between the cover 190 and cover 390 is that thecover 190 includes a raised portion or area 191. The raised portion 191of the cover 190 is included to provide room for the CSC 182 (as shownin FIG. 6).

Referring now to FIG. 12, a CSC 380 is shown according to an exemplaryembodiment. The CSC 380 is configured to monitor and/or regulate thetemperature, current, and/or voltage of the cells 130 and includes thenecessary sensors and electronics to do so (not shown). The CSC 380 mayreceive a signal from the BMS (e.g., the CSC may be a slave module tothe BMS) to balance or regulate the cells 130.

According to an exemplary embodiment, the CSC 380 includes thecomponents that would otherwise be present in a traceboard (e.g., suchas the traceboard 180 as shown in FIG. 6). By including the componentsof the traceboard (e.g., such as electrical contacts, conductive lines,connectors, sensors such as temperature sensors, voltage sensors,current sensors, etc.) within the CSC 380, the CSC 380 will have arelatively thinner profile than that of the combination of thetraceboard 180 and CSC 182 shown in FIG. 6. Therefore, a relativelythinner profile cover 390 may be utilized with the CSC 380.Additionally, the CSC 380 eliminates the need for an additionalcomponent (i.e., the traceboard), allowing greater speed and efficiencyin the assembly of the battery module and/or lower cost of the batterymodule.

Referring now to FIG. 13, a bus bar assembly 370 is shown according toan exemplary embodiment. The bus bar assembly 370 includes a base memberor substrate shown as a first layer 371 and a plurality of conductivemembers or elements shown as bus bars 373 coupled to the first layer371. Each bus bar 373 has an opening or aperture 374 at either endthereof that is accessible via an opening or aperture 375 in the firstlayer 371. The apertures 374 are configured to align with the terminalsof the electrochemical cells in order to electrically couple the cellstogether (e.g., by welding, fasteners, etc.). According to an exemplaryembodiment, the bus bar assembly 371 may include a second layer 372 thatis configured to sandwich the bus bars 373 in between the first layer371 and the second layer 372. According to an exemplary embodiment, thebus bars 373 are constructed from copper or copper alloy (or othersuitable material) and the first layer 371 and second layer 372 areconstructed from a polymeric material such as Mylar® (or other suitablematerial).

Referring now to FIGS. 14A and 14B, a body or housing 350 is shownaccording to an exemplary embodiment. An internal surface 359 of thehousing 350 is contoured to match the exterior shape of the cells 330.According to an exemplary embodiment, the housing 350 includes anexternal surface 351 that substantially complements the shape of theinternal surface 359 such that the housing 350 substantially matches theoffset configuration of the cells 330. Having the housing 350substantially match the exterior shape of the cells 330 allows portionsof the housing 350 to next with complementary features of a housing ofan adjacent battery module 324 when provided in a battery system. Asillustrated in this embodiment and in other embodiments of housingsshown and described in the present application, the undulating or wavywalls of the housing complement the shapes of the cells to allow closecontact between the housing and the cells and to allow for nesting ofthe housing with housings of adjacent battery modules in a batterysystem.

According to an exemplary embodiment, a top portion 352 of the housing350 includes a plurality of apertures 353, 354 configured to allow theterminals of the electrochemical cells 330 to pass through. For example,the aperture 353 may have a first diameter and the aperture 354 may havea second diameter that is smaller than the first diameter such that theterminals of the electrochemical cells 330 may only be received in theproper configuration. An interior side of the top portion of the housing350 includes a plurality of features or flanges 355 to generally fix(e.g., retain, hold, etc.) the upper end of the cells 330 and to holdthem in position in relation to the other cells 330. The housing 350 maybe made of a polymeric material or other suitable material (e.g., anelectrically insulative material).

Referring now to FIGS. 15A-15E, a heat exchanger 340 is shown accordingto an exemplary embodiment. The heat exchanger 340 is configured to beprovided between two rows of the electrochemical cells 330 as shown inFIG. 15E (e.g., the heat exchanger 340, as well as other embodiments ofheat exchangers shown and described in this application, have anundulating or wavy structure and/or otherwise has a shape that isintended to allow the heat exchanger to fit between the adjacent offsetrows of electrochemical cells such that the heat exchanger makes contactwith external surfaces of the cells). The heat exchanger 340 is providedwith a first opening or inlet 341 and a second opening or outlet 342. Amain body of the heat exchanger 340 has external surfaces 343 thatdefine a space between which fluid (e.g., a heating and/or cooling fluidsuch as a refrigerant, water, water/glycol mixture, etc.) may flowbetween opening 341 and opening 342.

The first and second openings 341, 342 act as inlets/outlets for thefluid. The openings 341, 342 may be provided with a quick-connectfeature to allow the heat exchanger 340 to be quickly and efficientlyconnected to a heat exchanger 340 of an adjacent battery module 324 orto a manifold (that provides the fluid for heating and/or cooling).

According to an exemplary embodiment, the fluid is a water/glycolmixture (e.g., a 50/50 water/glycol mixture), although according toother exemplary embodiments, the fluid may be any suitable type of fluidfor use in heating/cooling applications.

The external surface 343 of the heat exchanger 340 includes a pluralityof vertically-oriented troughs 344 (grooves, depressions, valleys, etc.)and peaks 345 that are configured to receive a portion of an exteriorsurface 338 of each of the electrochemical cells 330 to provide heattransfer to/from the electrochemical cells 330.

According to an exemplary embodiment, the heat exchanger 340 may be madeof a polymeric material (e.g., polypropylene) or other suitable materialthat allows for heat conduction to/from the cells 330 (e.g., anelectrically insulative and thermally conductive material). According toanother exemplary embodiment, the heat exchanger 340 may be made of ametallic material (e.g., aluminum or aluminum alloy) or other suitablematerial (e.g., when the external surface of the cells 330 are notelectrically charged (e.g., can neutral) or a separate electricallyinsulative and thermally conductive material is provided between thecells and the heat exchanger). According to another exemplaryembodiment, the heat exchanger 340 may be made of a ceramic material orother suitable material. According to an exemplary embodiment, the heatexchanger 340 may be made from a blow molding process, an injectionmolding process, or other suitable process.

As best shown in FIGS. 15D and 15E, the shape of the heat exchanger 340is configured to match the external shape of the electrochemical cells330 and is provided in physical contact with the cells 330. According toan exemplary embodiment, the portion of the heat exchanger 340 incontact with each cell 330 (i.e., the angle of contact “C”) isapproximately the same for each cell 330. According to a particularexemplary embodiment, the angle of contact C is approximately 111degrees. According to another exemplary embodiment, the angle of contactC may be varied for each cell 330 in order to provide even heatingand/or cooling to each cell 330 (e.g., to compensate for the drop/risein temperature of the fluid as it flows through the heat exchanger 340).

According to an exemplary embodiment, the wall thickness of the heatexchanger 340 is between approximately 0.5 millimeters and 1.5millimeters. According to another exemplary embodiment, the wallthickness of the heat exchanger 340 is approximately 1 millimeter.According to an exemplary embodiment, the overall thickness of the heatexchanger 340 is between approximately 4 millimeters and 36 millimeters.According to another exemplary embodiment, the overall thickness of theheat exchanger 340 is approximately 16 millimeters. According to otherexemplary embodiments, the wall thickness and/or overall thickness ofthe heat exchanger 340 may vary according to other exemplaryembodiments.

Referring now to FIG. 16, an inlay 362 is shown being provided in a tray360 (e.g., base, bottom, structure, etc.) according to an exemplaryembodiment. The inlay 362 may be constructed from EPDM foam (or anyother suitable material) and is configured to seal the individual cellsfrom any gases that are vented from other cells 330. The inlay 362 isconfigured to open (e.g., tear) if the vent device of theelectrochemical cell 330 is deployed, allowing the vented gases from thecell to pass through the inlay 362. The inlays 362 also take up anydimensional tolerance variation of the battery module 324 duringassembly. Additionally, the inlay 362 may aid in isolating theelectrochemical cells 330 from vibrations (e.g., during operation of thevehicle).

As shown in FIG. 16, the inlay 362 includes a plurality ofcircular-shaped disks that are connected to one another by an element orconnecting portion 363. As shown in FIG. 16, a single row of inlays 362is provided for each row of cells. However, the inlays 362 may beprovided as individual inlays 362 (e.g., individual circular disks) foreach individual electrochemical cell 330 according to another exemplaryembodiment.

According to an exemplary embodiment, the tray 360 is provided with aplurality of features or sockets each having a flange or wall 364. Thewalls 364 aid in retaining the lower end of the cells 330 in relation toeach other. The sockets also include a plurality of apertures 361 thatallow gases and/or effluent to pass through if the cell 330 should vent(via the vent 336). According to an exemplary embodiment, the tray 360is constructed from a polymeric material and is coupled to the body viafasteners. According to another exemplary embodiment, the tray 360 mayotherwise be fastened to the body (e.g., with a snap-fit connection,glued, etc.). The tray 360 is configured to receive the inlay 362therein, and cutouts 365 are provided between adjacent spaces to allowthe connecting portions or elements that connect the circular-shapeddisks together to pass therethrough.

Referring now to FIG. 17, a perspective view of a battery module 424 isshown according to another exemplary embodiment. The battery module 424may include many of the same or similar features as previously discussedwith respect to FIGS. 1-16. Therefore, only a few of the features of thebattery module 424 will be discussed in more detail below.

The battery module 424 includes a plurality of electrochemical cells orbatteries (e.g., lithium-ion cells, nickel-metal-hydride cells, lithiumpolymer cells, etc., or other types of electrochemical cells now knownor hereafter developed). According to an exemplary embodiment, theelectrochemical cells (not shown) are generally cylindrical lithium-ioncells configured to store an electrical charge. According to otherexemplary embodiments, the cells could have other physicalconfigurations (e.g., oval, prismatic, polygonal, etc.). The capacity,size, design, and other features of the cells may also differ from thoseshown according to other exemplary embodiments.

According to an exemplary embodiment, the electrochemical cells arearranged in two rows of six cells each for a total of twelve cells.However, the battery module 424 may include a greater or lesser numberof cells according to other exemplary embodiments. The cells arepartially or substantially enclosed by a housing 450 and a lower portionor tray 460. The housing 450 has an interior surface substantiallyconforming to the exterior of the cells. The housing 450 also has anexternal surface substantially conforming to the exterior of the cells(e.g., the external surface of the housing is complementary to theinternal surface of the housing). As such, the housing 450 is configuredto be nested with an adjacent battery module 424 to efficiently use thespace within a battery system (not shown).

The battery module 424 also includes a bus bar assembly 470 (e.g., suchas shown in FIG. 18). The bus bar assembly 470 includes a base member orsubstrate and a plurality of conductive members or elements that areconfigured to electrically couple one or more of the electrochemicalcells or other components of the battery module 424 together.

According to an exemplary embodiment, the bus bar assembly 470 includesa plurality of bus bars 473 provided on a first layer or substrate 471(e.g., a plastic or film such as Mylar®). According to anotherembodiment, a second layer 472 may be provided to sandwich the pluralityof bus bars 473 between the first layer 471 and the second layer 472. Asshown in FIG. 18, each of the plurality of bus bars 473 includes anaperture or opening 474 provided at each end of each of the bus bars473. These openings 474 are configured to receive a fastener 489 inorder to couple the bus bar 473 to a terminal of an electrochemicalcell.

The battery module 424 further includes a traceboard 480 and a CSC 482(e.g., such as shown in FIG. 19). According to exemplary embodiment, thetraceboard 480 includes a plurality of flexible contacts 484. Theflexible contacts 484 may be similar to the flexible contacts 584 asshown as described in FIG. 33A. According to an exemplary embodiment,the flexible contacts 484 may be connected to connectors 483 by aplurality of conductive lines or wires (not shown). According to anexemplary embodiment, the traceboard 480 may also include a plurality ofvarious sensors (e.g., voltage sensors, temperature sensors, etc.) andother electrical components.

According to an exemplary embodiment, the CSC 482 may be mechanicallycoupled (e.g., by fasteners) to the traceboard 480. Additionally, theCSC 482 may be electrically coupled with the traceboard 480 by a cableor connector (not shown). The CSC 482 is configured to monitor and/orregulate the temperature, current, and/or voltage of the electrochemicalcells and includes the necessary sensors and electronics to do so (notshown).

The battery module 424 further includes a heat exchanger 440 (e.g., suchas shown in FIG. 20) that is provided in between the two rows ofelectrochemical cells to provide heating and/or cooling to the cells.The heat exchanger 440 includes a plurality of individual cooling bandsor portions (e.g., fluid flow segments) shown as discrete paths 448connected at their ends by connecting portions or manifolds 446, 447 andseparated from each other by gaps 449 (although shown as gaps 449,according to other exemplary embodiments, the gaps may be replaced bysolid portions within the heat exchanger that divide the paths from eachother).

In this manner, the fluid flow through the heat exchanger is dividedinto multiple segments that extend between the inlet manifold and theoutlet manifold (i.e., the fluid flows in one direction through the heatexchanger, from the inlet manifold to the outlet manifold, with thefluid divided into multiple segments or paths as it flows through themanifold). According to an exemplary embodiment, the heat exchanger 440includes a first opening 441 and a second opening 442 which areconfigured to act as inlets/outlets for the cooling/heating fluid.

As shown in FIG. 20, the heat exchanger 440 includes five individualpaths 448, but may include a greater or lesser number of paths 448according to other exemplary embodiments. Each of the paths 448 isconfigured to allow a fluid to flow therethrough (i.e., the outer wallsof each of the paths 448 define a space through which the fluid mayflow). The heat exchanger 440 is configured to aid in providing evenheating and/or cooling to the cells (e.g., by avoiding any “dead spots”or areas of non-moving fluid).

According to an exemplary embodiment, the fluid enters the opening 441and flows into the manifold 446. From the manifold 446, the fluid flowsfrom the first end of the heat exchanger 440 towards the second end ofthe heat exchanger 440 through any of the multiple discrete paths 448.The fluid then exits the discrete paths 448 and enters the manifold 447,where the fluid then exits the heat exchanger 440 through the opening442. According to another exemplary embodiment, the fluid may flow inthe opposite direction (i.e., the fluid may enter the opening 442 andexit the opening 441).

According to an exemplary embodiment, the heat exchanger 440 may be madeof a polymeric material (e.g., polypropylene) or other suitable materialthat allows for heat conduction to/from the cells (e.g., an electricallyinsulative and thermally conductive material). According to anotherexemplary embodiment, the heat exchanger 440 may be made of a metallicmaterial (e.g., aluminum or aluminum alloy) or other suitable material(e.g., when the external surface of the cells are not electricallycharged (e.g., can neutral) or a separate electrically insulative andthermally conductive material is provided between the cells and the heatexchanger). According to another exemplary embodiment, the heatexchanger 440 may be made of a ceramic material or other suitablematerial. According to an exemplary embodiment, the heat exchanger 440may be made from a blow molding process, an injection molding process,or other suitable process.

Referring now to FIGS. 21-35, a method of assembling a battery module524 is shown according to an exemplary embodiment. As shown in FIG. 21,the battery module 524 includes a structure shown as a housing 550(shown upside down). The housing 550 includes a plurality of openings orapertures 559 that are configured to allow a liquid (e.g., condensate,effluent and/or gases vented from electrochemical cells within thehousing, etc.) to exit the housing 550. The apertures 559 may be locatedin various positions throughout the housing 550 depending on theorientation that the module 524 is mounted. The housing 550 alsoincludes a plurality of structures shown as ribs 551 provided on anexternal surface of the housing 550. According to an exemplaryembodiment, the ribs 551 provide additional structural rigidity to thehousing 550 and/or may be used in forming the housing 550.

Referring now to FIG. 22, a heat exchanger 540 is provided within thehousing 550. The heat exchanger 540 includes a first opening 541 and asecond opening 542. As shown in FIGS. 22A-22B, the first opening 541 isprovided in a slot or cutout 558 in the housing 550 and the secondopening 542 is provided in an opening or aperture 557 in the housing550. According to an exemplary embodiment, the opening 541 is an inletconfigured to receive a fluid (e.g., water, water/glycol mixture,refrigerant, etc.) and the opening 542 is an outlet. According toanother exemplary embodiment, the opening 542 may be an inlet and theopening 541 may be an outlet.

As shown in FIGS. 23-25, the heat exchanger 540 includes externalsurfaces 543 that are configured to receive a portion of an externalsurface 538 of the electrochemical cells 530 (e.g., as shown in FIG.26). The external surfaces 538 include vertically orientated troughs orgrooves 544 and peaks or ridges 545. The heat exchanger 540 may alsoinclude a portion 546 at either end of the heat exchanger 540.

According to an exemplary embodiment, the heat exchanger 540 includes adiscrete path 548 through which the fluid flows through the heatexchanger 540. According to an exemplary embodiment, the flow of thefluid inside the heat exchanger 540 may be in a zig-zag motion (e.g., asshown by arrow 547 in FIG. 23), but may vary according to otherexemplary embodiments. According to one exemplary embodiment, thediscrete path 548 may be separated by a gap 549 (or, alternatively,there may be solid material between the paths rather than a gap toseparate the various parts of the winding path from each other).

In this manner, the fluid may be routed through the heat exchanger suchthat it passes past each of the cells multiple times as it zig-zagsthrough the heat exchanger. Similar to the fluid flow within the heatexchanger described with respect to FIG. 20, the fluid flow through theheat exchanger is divided into multiple segments that are separated fromeach other, although instead of flowing in a single direction between aninlet or an outlet, the fluid in the heat exchanger 540 reverses itsflow direction as it transitions between one segment of the fluid flowpath and the adjacent segment of the fluid flow path.

For example, as shown in FIG. 23, the fluid may enter the heat exchanger540 at an opening 541 at a first end of the heat exchanger 540. Thefluid then flows lengthwise through the heat exchanger 540 toward asecond end along the path 548. At the second end, the path 548 thenturns 180° so that the flow of the fluid is back towards the first end(i.e., in the opposite direction). Once the fluid reaches the first end,the path 548 then again turns 180° so that the flow of the fluid isagain towards the second end. The fluid then follows the path 548 untilthe fluid reaches the opening 542 to exit the heat exchanger.

According to another exemplary embodiment, the flow of the fluid may bein the opposite direction (i.e., the fluid may enter the opening 542 andexit the opening 541 after flowing through the path 548). According tovarious exemplary embodiments, the design of the heat exchanger 540 mayvary (e.g., the heat exchanger may include any number of turns orlengths of the path 548 for as many times as needed to properlyheat/cool the electrochemical cells 530).

According to other exemplary embodiments, the fluid may flow through theheat exchanger 540 in a variety of ways. For example, the fluid may flowin a generally vertical zig-zag motion (instead of the previouslydescribed horizontal zig-zag motion). According to another exemplaryembodiment, the heat exchanger 540 may be hollow inside (i.e., containsno internal partitions, walls, or separations) so that the fluid flowsdirectly from the inlet (e.g., opening 541) to the outlet (e.g., opening542) of the heat exchanger 540.

According to an exemplary embodiment, the heat exchanger 540 may be madeof a polymeric material (e.g., polypropylene) or other suitable materialthat allows for heat conduction to/from the cells 530 (e.g., anelectrically insulative and thermally conductive material). According toanother exemplary embodiment, the heat exchanger 540 may be made of ametallic material (e.g., aluminum or aluminum alloy) or other suitablematerial (e.g., when the external surface of the cells 530 are notelectrically charged (e.g., can neutral) or a separate electricallyinsulative and thermally conductive material is provided between thecells and the heat exchanger). According to another exemplaryembodiment, the heat exchanger 540 may be made of a ceramic material orother suitable material. According to an exemplary embodiment, the heatexchanger 540 may be made from a blow molding process, an injectionmolding process, or other suitable process. According to an exemplaryembodiment, the internal partitions, walls, or separations are formed bypinching or welding together the external walls of the heat exchanger540.

According to an exemplary embodiment, the wall thickness of the heatexchanger 540 is between approximately 0.5 millimeters and 1.5millimeters. According to another exemplary embodiment, the wallthickness of the heat exchanger 540 is approximately 1 millimeter.According to an exemplary embodiment, the overall thickness of the heatexchanger 540 is between approximately 4 millimeters and 6 millimeters.According to another exemplary embodiment, the overall thickness of theheat exchanger 540 is approximately 4.6 millimeters. According to anexemplary embodiment, the wall thickness and/or the overall thickness ofthe heat exchanger 540 is substantially constant along the length of theheat exchanger 540 (such as, e.g., shown in FIG. 24). According to otherexemplary embodiments, the wall thickness and/or overall thickness ofthe heat exchanger 540 may vary according to other exemplaryembodiments.

Referring now to FIGS. 26-26B, a plurality of electrochemical cells 530are provided (upside down) within the housing 550. According to anexemplary embodiment, the electrochemical cells 530 are generallycylindrical lithium-ion cells configured to store an electrical charge.According to other exemplary embodiments, the cells may benickel-metal-hydride cells, lithium polymer cells, etc., or other typesof electrochemical cells now known or hereafter developed. According toother exemplary embodiments, the electrochemical cells 530 could haveother physical configurations (e.g., oval, prismatic, polygonal, etc.).The capacity, size, design, and other features of the electrochemicalcells 530 may also differ from those shown according to other exemplaryembodiments.

According to an exemplary embodiment, the electrochemical cells 530include a positive terminal 532 and a negative terminal 534 that areconfigured to be received within apertures 553, 554 located on an uppersurface of the housing 550, respectively. According to an exemplaryembodiment, the apertures 553, 554 are sized differently relative to oneanother such that the terminals 532, 534 may only be provided within thehousing 550 in the proper orientation. According to an exemplaryembodiment, the electrochemical cells 530 are rotated until theterminals 532, 534 properly align with the apertures 553, 554.

According to an exemplary embodiment, the terminals 532, 534 include athreaded opening 533, 535 configured to receive a fastener in order tocouple a conductive member of the bus bar 573 (e.g., as shown in FIG.31). The upper surface of the housing 550 may also include a projection555 having a threaded opening 556 configured to receive a fastener inorder to couple a CSC 582 to the battery module 524 (e.g., as shown inFIG. 34).

Referring now to FIGS. 27A and 27B, at least one temperature sensor maybe provided within the housing 550 to measure the temperature of one ofthe cells 530. For example, as shown in FIG. 27A, a temperature sensor501 is provided in a cutout or slot 502 provided in the housing 550. Thetemperature sensor 501 is connected (e.g., via connecting wires 503) toa traceboard (e.g., such as traceboard 580 shown in FIG. 32) and fromthere to a CSC (e.g., such as CSC 582 shown in FIG. 34) or a batterymanagement system.

According to another exemplary embodiment, a temperature sensor 504 maybe provided in a cutout or slot 505 provided in the housing 550 andconnected (e.g., by a connecting wire 506) to a traceboard (e.g., suchas traceboard 580 shown in FIG. 32) and from there to a CSC (e.g., suchas CSC 582 shown in FIG. 34) or a battery management system. In eithercase, an electrochemical cell 530 is then provided within the housing550 and makes contact with the sensor 501, 504. According to anexemplary embodiment, the sensor 501, 504 is located approximately at amid-section of the electrochemical cell 530, but according to otherexemplary embodiments, the sensor 501, 504 may be located elsewhere.

Referring now to FIG. 28, a structure or a base shown as a tray 560 isshown according to an exemplary embodiment. The tray 560 includes aninternal wall or surface 565 configured to substantially match a portionof the exterior 538 of the electrochemical cells 530. According toanother exemplary embodiment, an external surface of the tray 560 isessentially complementary to the internal surface 565. According toanother exemplary embodiment, the tray 560 includes a plurality offeatures or sockets 566 configured to receive a lower end of each of theelectrochemical cells 530. The sockets may include a first diameter 561configured to receive an inlay 562. According to an exemplaryembodiment, each inlay 562 has an internal diameter that is generallyaligned with the internal diameter 563 of the sockets.

The inlays 562 may be constructed of a flexible material such as EPDMfoam (or any other suitable material). The inlays 562 are configured totake up any dimensional tolerance variation of the battery module 524during assembly. Additionally, the inlay 562 may aid in isolating theelectrochemical cells 530 from vibrations (e.g., during operation of thevehicle).

According to an exemplary embodiment, the tray 560 also includes afeature shown as a projection or protrusion 568 that is configured to atleast partially retain or aid in the positioning of the lower ends ofthe cells 530. According to another exemplary embodiment, theprotrusions 568 may also aid in the positioning of the heat exchanger540. The tray 560 also includes a plurality of openings or cut-outs 567that are in fluid communication with the internal diameter 563 of thesockets 566 of the tray 560 such that gas and/or effluent that may bevented from the electrochemical cell 530 may then exit through theopening 567.

The tray 560 also includes a feature or wall 564 that extends from theinternal diameter 563 of the sockets 566 above a bottom surface 569 ofthe tray 560. These walls 564 may act as a vent opening feature for thevent 536 of the electrochemical cells 530. An example and description ofa vent opening feature may be found in International Application No.PCT/US2009/053697, filed Aug. 13, 2009, the entire disclosure of whichis incorporated herein by reference.

According to the exemplary embodiment shown in FIGS. 29 and 29A, thetray 560 is coupled to the housing 550 with a plurality of fasteners.According to other exemplary embodiments, the tray 560 may be coupled tothe housing 550 by other means (e.g., a snap-fit connection, welding,etc.). According to an exemplary embodiment, as shown in FIG. 29A, thehousing 550 may include a slot 510 provided in a feature or rib 509 andconfigured to receive a nut 511. The slot 510 is shaped to restrictmovement of the nut 511 while a fastener 508 is being threaded into thenut 511. As shown, the tray 560 includes an aperture or opening 507configured to receive the fastener 508 therethrough. According toanother exemplary embodiment, the tray 560 may include the slot 510instead of the housing 550.

According to an exemplary embodiment, the battery module 524 may bevaried in order to accommodate smaller or larger electrochemical cells530. For example, the housing 550 may be varied in height in order toaccommodate shorter or longer electrochemical cells. According toanother exemplary embodiment, the tray 560 may be varied in height inorder to accept shorter or longer electrochemical cells. In yet anotherexemplary embodiment, both the housing 550 and the tray 560 may bevaried in height in order to accommodate shorter or longerelectrochemical cells. According to another exemplary embodiment, theheat exchanger 540 may be varied in height in order to accommodateshorter or longer electrochemical cells.

Referring now to FIGS. 30 and 30A, nuts 514 are provided within openings513 located in a top surface of the housing 550. Nuts 514 are configuredto be used in connecting the module 524 with an adjacent module or toother components within a battery system (not shown). Also shown in FIG.30 are projections 512 provided throughout the upper surface of thehousing 550. According to an exemplary embodiment, the projections 512surround at least a portion of a terminal 532, 534 of theelectrochemical cells 530. As can be seen in FIG. 31, the projections512 aid in isolating the bus bars 573 from one another. According to anexemplary embodiment, the projections 512 may be arcuate in nature ormay otherwise be configured (e.g., rectilinear).

Referring now to FIG. 31, a bus bar assembly 570 is shown coupled to thebattery module 524 according to an exemplary embodiment. The bus barassembly 570 includes conductive members or bus bars 573 used to connectthe electrochemical cells 530 to one another or to other components ofthe battery module or battery system. Having the bus bars 573 as part ofthe bus bar assembly 570 saves time and assembly costs when assemblingthe battery module 524.

According to an exemplary embodiment, the bus bar assembly 570 includesa plurality of bus bars 573 provided on a first layer or substrate 571(e.g., a plastic or film such as Mylar®). According to anotherembodiment, a second layer (not shown) may be provided to sandwich theplurality of bus bars 573 between the first layer 571 and the secondlayer. As shown in FIG. 31, each of the plurality of bus bars 573includes an aperture or opening 574 provided at each end of each of thebus bars 573. These openings 574 are configured to receive a fastener inorder to couple the bus bar 573 to a terminal (e.g., such as a positiveterminal 532 or a negative terminal 534 as shown in FIG. 30).

Referring now to FIG. 31A, a temperature sensor 576 is shown beingprovided to the housing 550 according to an exemplary embodiment. Thetemperature sensor 576 is inserted into a hole or opening 575 located ona top portion of the housing 550. The temperature sensor 576 may beconnected (e.g., by a connecting wire) to a traceboard (e.g., such astraceboard 580 shown in FIG. 32) and from there to a CSC (e.g., such asCSC 582 shown in FIG. 34) or a battery management system. A seal orO-ring 577 surrounds the connecting wire to seal the opening 575. Aretaining member shown as a clip 578 is provided to retain thetemperature sensor 576 in place. The clip 578 has an opening or aperturefor the connecting wire to fit through. The clip 578 also has a pair ofarms to aid in retaining the clip 578 to the housing 550.

Referring now to FIGS. 32-33A, a traceboard 580 is shown according to anexemplary embodiment. The traceboard 580 includes various electronic andelectrical components (e.g., electrical contacts, sense lines, sensors,connectors 583, etc.) in order to monitor, control, and/or regulate thecells 530. For example, the traceboard 580 includes a plurality offlexible spring leads or flexible contacts 584. The flexible contacts584 are used to connect the sensors 579 on the traceboard 580 to theterminals 532, 534 of the cells 530 in order to measure the voltage ofthe various cells 530. Having a flexible contact 584 allows formisalignment and/or dimensional variation of the components during theassembly process. The flexible contact 584 also isolates the traceboard580 from vibration (e.g., from the vehicle).

As shown in FIG. 33A, the flexible contact 584 includes a main bodyportion 585 generally in the shape of a circular ring or washer. Themain body 585 is connected to outer members 586 by a plurality ofmembers or arms 587. As show in FIG. 33A, the flexible contact 584 hastwo arms 587; however, according to other exemplary embodiments, theflexible contact 584 may have a greater or lesser number of arms 587.The main body 585 has an aperture or opening 588 that is configured toallow a fastener 589 therethrough in order to couple the flexiblecontact 584 with a terminal of the electrochemical cell 530. The outermembers 586 are configured to be coupled (e.g., soldered, welded, etc.)to the traceboard 580.

According to an exemplary embodiment, the flexible contacts 584 areformed from a stamping process or other suitable process. According toan exemplary embodiment, the flexible contacts 584 are formed from aconductive material such as copper (or copper alloy), aluminum (oraluminum alloy), or other suitable material. According to an exemplaryembodiment, the flexible contacts 584 have a constant resistance acrossthe voltage lead of the electrochemical cell 530.

Referring now to FIG. 34, a CSC 582 is shown being assembled to thetraceboard 580 of the battery module 524 according to an exemplaryembodiment. The CSC 582 is configured to monitor and/or regulate thetemperature, current, and/or voltage of the electrochemical cells 530.Also shown in FIG. 34 are connector wires 503, 506 that connecttemperature sensors 501, 504 (e.g., as shown in FIGS. 27A and 27B) tothe connector 583. The connector 583 is conductively connected to theCSC 582 (e.g., by electrical or conductive lines (not shown)).Additionally, the traceboard 580 (e.g., via a main connector (notshown)) may be conductively coupled to the CSC 582.

Referring now to FIGS. 35 and 35A, a cover 590 is shown according to anexemplary embodiment being coupled to the housing 550 of the batterymodule 524. According to an exemplary embodiment, the cover 590 includesa raised portion 591 configured to correspond with the CSC 582.Additionally, raised portions 592 are provided on the cover 590 thatcorrespond with the connectors 583. According to an exemplaryembodiment, raised portions 592 include an opening 593 to allow accessto the connectors 583.

According to an exemplary embodiment, the cover 590 is coupled to thehousing 550 (e.g., with a snap-fit connection). As shown in FIG. 35A,the cover 590 includes a snap-hook 594 having a protrusion 595 thatengages an opening or aperture 596 in the housing 550. The protrusion595 of the snap-hook 594 engages a surface or ledge 597 that surroundsthe opening 596 to couple the cover 590 to the housing 550. According toanother exemplary embodiment, the housing 550 may include the snap-hook594 feature and the cover 590 may include the opening 596. According toother exemplary embodiments, the cover 590 may be otherwise coupled tothe housing 550 (e.g., by fasteners, adhesives, welding, etc.).

Referring now to FIGS. 36 and 37, a battery module 624 is shownaccording to another exemplary embodiment. The battery module 624includes a housing 650 configured to receive a plurality ofelectrochemical cells 630 in a housing 650. A lower housing or tray 660is provided coupled to a bottom portion of the housing 650. A cover 690is coupled (e.g., with a snap-fit connection, fasteners, adhesive,welding, etc.) to the housing 650. According to FIG. 37, the batterymodule 624 includes a heat exchanger 640 provided within the housing 650in order to provide heating and/or cooling to the electrochemical cells630. The heat exchanger 640 includes fluid connections (e.g., such asconnection 641) in order to connect the heat exchanger 640 to a fluid(e.g., water, water/glycol mixture, refrigerant, etc.).

According to an exemplary embodiment, the housing 650 includes a memberor flange 651 having a cut-out or recess 605. Recess 605 is configuredto receive a temperature sensor (not shown) to measure the temperatureof an electrochemical cell 630. According to an exemplary embodiment,the temperature sensor is provided at a midway point along the height ofthe cell 630. According to other exemplary embodiments, the temperaturesensor may be provided at other locations in the battery module 624and/or at different heights along the electrochemical cell 630.

Referring now to FIGS. 38A-41C, a battery system 722 is shown accordingto another exemplary embodiment. The battery system 722 includes aplurality of battery modules 724 located adjacent one another (e.g.,side-by-side). As shown in FIG. 38A, the battery system 722 includesseven battery modules 724. According to other exemplary embodiments, thebattery system 722 may include a greater or lesser number of batterymodules 724. The battery system also includes a battery managementsystem (BMS) 728 configured to monitor, regulate, and/or control thebattery system 722 and/or battery modules 724.

Although illustrated in FIGS. 38A-41C as having a particular number ofbattery modules 724 (i.e., seven battery modules), it should be notedthat according to other exemplary embodiments, a different number and/orarrangement of battery modules 724 may be included in the battery system722 depending on any of a variety of considerations (e.g., the desiredpower for the battery system, the available space within which thebattery system must fit, etc.). The design and construction of thebattery modules 724 allow for modular assembly (e.g., the modules may bequickly and efficiently mechanically, electrically, and/or thermallycoupled to one another or with other components of the battery system722).

As shown in FIG. 39, a vehicle chamber 710 is shown configured toreceive the battery system 722. The vehicle chamber 710 includes a firstlevel 711 and a second level 712 configured to correspond with a housing720 of the battery system 722. According to an exemplary embodiment, thefirst level 711 includes an opening 713 (e.g., to allow vented gasesfrom the individual cells (not shown) of the battery modules 724 to passtherethrough). According to another exemplary embodiment, the secondlevel 712 includes an opening 714 (e.g., to allow electrical connectionsor wires to pass through in order to be connected to the battery system722, such as, e.g., the BMS 728).

As shown in FIG. 38B, the battery system 722 includes a plurality ofopenings or slots 721 located at the bottom of the battery systemhousing 720 through the slot 721 of the battery system housing 720 andinto a chamber. The chamber is defined by the bottom of the batterysystem housing 720 and the structure of the vehicle chamber 710 (e.g.,as shown in FIG. 31). According to an exemplary embodiment, the chambermay include at least one hole or opening (e.g., opening 713) through thebottom of the vehicle chamber 710 that allows the vented gases from thechamber to exit the vehicle.

According to an exemplary embodiment, the slot or opening 721 at thebottom of the battery system housing 720 runs substantially along theentire length of each individual battery module 724. According toanother exemplary embodiment, the slot or opening 721 overlaps two rowsof electrochemical cells of the individual battery module 724. Accordingto another exemplary embodiment, the slots or openings 721 onlypartially uncover the vents of the cells of the battery module 724, butstill allow the vents to be in fluid communication with the chamber viathe slot or opening 721.

Referring to FIGS. 38A and 40A-40C, the battery system 722 is also shownto include a first manifold 702 connected to an opening or inlet 741(e.g., as shown in FIG. 40B) of the heat exchangers (not shown) of thebattery module 724. The battery system 722 also includes a secondmanifold 704 coupled to the heat exchanger (not shown) of the batterymodules 724. The manifolds 702, 704 are configured to provide a fluid toheat and/or cool the electrochemical cells of the battery modules 724.

According to an exemplary embodiment, the manifolds 702, 704 may becoupled (e.g., via connections 700, 701) to a heat exchanger (not shown)of the vehicle in order to heat and/or cool the fluid used to manage thetemperature of the electrochemical cells in the battery system 722.According to an exemplary embodiment, the manifolds 702, 704 extendtransversely across the individual battery modules 724 (e.g., eitherside of the battery system 722). According to other exemplaryembodiments, the manifolds 702, 704 may be located elsewhere in thebattery system 722 or in a different configuration.

According to an exemplary embodiment, the manifold 702 is configured tobe an inlet or supply manifold to the battery module 724 and themanifold 704 is configured to be an outlet or return manifold for thebattery module 724. According to another exemplary embodiment, themanifold 724 may be the inlet manifold and the manifold 702 may be theoutlet manifold.

As shown in FIGS. 38A and 40A-40C, the manifolds 702, 704 are connectedto the connections of the heat exchangers by a member or connection 703,705. According to an exemplary embodiment, (e.g., as shown in FIG. 40B)the connections 703, 705 exit the manifold 702, 704 at the top of themanifolds 702, 704 and then connect with the inlets/outlets (e.g.,openings 741) of the heat exchangers. According to other exemplaryembodiments, the connections 703, 705 may be otherwise connected fromthe manifolds to the heat exchangers. According to an exemplaryembodiment, each manifold 702, 704 may include an inlet/outletconnection 701, 700 (e.g., as shown in FIG. 40C) for receiving theheating/cooling fluid.

Referring now to FIGS. 41A and 41B, a service disconnect 706 for thebattery system 722 is shown according to an exemplary embodiment. Theservice disconnect 706 is configured to disconnect the high voltageconnections of the battery system 722 before the battery system 722 maybe serviced. As shown in FIG. 41A, the service disconnect 706 is in anON or connected position. As shown in FIG. 41B, the service disconnect706 is in an OFF or disconnected position.

According to an exemplary embodiment, the service disconnect 706includes a main body portion 708 and a handle portion 707. According toan exemplary embodiment, the handle 707 may include an opening oraperture therein configured to allow a user to more easily operate theservice disconnect 706. According to another exemplary embodiment, theservice disconnect 706 may include a feature or device shown as a catchor hook 709 configured to releasably engage with a portion of the handle707 when the service disconnect 706 is in the ON or connected position(e.g., as shown in FIG. 41A). According to other exemplary embodiments,any components of the service disconnect 706 may be provided in analternative configuration.

One advantageous feature of the service disconnect 706 is that afastener 715 that is used to couple a cover 719 to the battery systemhousing 720 is hidden (i.e., not accessible) when the service disconnectis in the ON position, as shown in FIG. 41A. In order to access thefastener 715, the handle 707 of the service disconnect 706 must berotated to the OFF position as shown in FIG. 41B. Thus, a user may nothave access to the battery system 722 when the service disconnect is inthe ON position (i.e., the user may only remove the cover 719 when theservice disconnect is in the OFF position).

Referring now to FIGS. 42-45, a battery system 822 is shown according toanother exemplary embodiment. As best seen in FIG. 42, the batterysystem 822 includes a housing 820 configured to receive a plurality ofbattery modules 824. According to various exemplary embodiments, thebattery modules 824 may be the same or similar to the various modulesdiscussed in this application or are otherwise known or hereinafterdeveloped.

According to an exemplary embodiment, the battery modules 824 arearranged in multiple layers (e.g., two layers), with each layer havingseven battery modules 824 arranged side-by-side. According to otherexemplary embodiments, a greater or lesser number of battery modules 824may be included in each layer. According to another exemplaryembodiment, a greater or lesser number of layers of the battery modules824 may be included in the battery system 822.

Although illustrated in FIGS. 42-45 as having a particular number ofbattery modules 824, it should be noted that according to otherexemplary embodiments, a different number and/or arrangement of batterymodules 824 may be included in the battery system 822 depending on anyof a variety of considerations (e.g., the desired power for the batterysystem, the available space within which the battery system must fit,etc.). The design and construction of the battery modules 824 allow formodular assembly (e.g., the modules may be quickly and efficientlymechanically, electrically, and/or thermally coupled to one another orwith other components of the battery system 822).

As shown in FIG. 42, each layer of the battery modules 824 is arrangedwithin a frame or member 818 (e.g., constructed from a metal or othersuitable material) that is configured to be provided within the housing820 and coupled thereto. Separating the layers of the battery modules824 is a structure or member shown as a plate or shelf 819.Additionally, a structure or member shown as a cover 821 is provided tosubstantially cover the battery modules 824 within the housing 820.According to an exemplary embodiment, the shelf 819 and the cover 821are constructed from sheet metal or other suitable material.

Referring now to FIG. 43, the battery system 822 is shown to include abase frame member or structure 816 (e.g., constructed from metal tubingor other suitable material). According to an exemplary embodiment,member 816 is configured to be coupled (e.g., with fasteners, welding,etc.) to a bottom of the housing 820 to aid in coupling the batterysystem 822 to a vehicle. According to another exemplary embodiment, thebattery system 822 may be provided as a stationary system (e.g., withina building) to provide stand-alone power. The battery system 822 alsoincludes a plurality of members 812 to aid in lifting the battery system822.

As shown in FIG. 43, the housing 820 may include a hole or opening 811configured to aid in the drainage of fluids and/or gases that may bevented from the individual cells within the battery modules 824 and/orcondensation or other liquids that may accumulate within the housing820. The battery system 822 also includes high voltage connections 814,815 configured to electrically connect the battery system 822 to thevehicle or other source requiring battery power. The battery system 822also includes a low voltage connector 813.

Referring now to FIGS. 44-45, the individual electrochemical cells (notshown) of the battery modules 824 of the battery system 822 may havetheir temperature regulated by a thermal management system utilizingliquid cooling and/or heating. For clarity, the thermal management ofthe electrochemical cells will be described below in regard to cooling.A liquid coolant (e.g., a fluid such as water, water/glycol mix,refrigerant, etc.) is provided to the battery modules 824 through amanifold 802. The manifold 802 is connected to the individual batterymodules 824 by a connecting member 803. The connecting member 803fluidly connects (e.g., provided in fluid communication) the manifold802 to the opening 841 of the heat exchanger (not shown) of theindividual battery modules 824. According to an exemplary embodiment, aclamping member shown as a hose clamp 806 may be included at the end ofeach connecting member 803 to aid in sealing the manifold 802 to theheat exchanger of the battery module 824.

According to another exemplary embodiment, a second manifold 804 isprovided with the battery system 822. The manifold 804 is fluidlyconnected (e.g., provided in fluid communication) to each of the batterymodules 824 by a connecting member 805. The connecting members 805connect the manifold 804 to the openings 842 of the heat exchangers ofthe individual battery modules 824.

According to one exemplary embodiment, the manifold 802 is a supply(inlet) manifold and the manifold 804 is a return (outlet) manifold.However, according to another exemplary embodiment, the manifold 804 maybe a supply manifold and the manifold 802 may be a return manifold. Thebattery system 822 includes fluid connections 800, 801 that areindividually connected with the manifolds 802, 804. According to oneexemplary embodiment, fluid connection 800 is an outlet connection whilethe fluid connection 801 is a supply or inlet connection. However,according to another exemplary embodiment, the fluid connection 800 isan inlet connection while the fluid connection 801 is an outletconnection.

According to an exemplary embodiment, the manifolds 802, 804 (andcorresponding fluid connections with the battery modules 824) are alllocated substantially on one side of the battery system 822. This allowseasy and efficient assembly and maintenance of the battery system 822.Likewise, while the fluid connections are all on one side of the batterymodule 824, substantially all of the electrical connections of thebattery modules 824 occur on one side of the battery system 822 (e.g.,the side opposite of the fluid connections).

Referring now to FIGS. 46 and 47, a battery system 922 is shownaccording to another exemplary embodiment. The battery system 922includes a plurality of battery modules 924 arranged side-by-side nextto one another to form a row. According to other exemplary embodiments,the battery modules 924 may be otherwise arranged (e.g., end-to-end,stacked, etc.). According to other exemplary embodiments, the batterymodules 924 may be the same or similar to the various modules discussedin this application or otherwise known or are hereafter developed.

According to an exemplary embodiment, the battery system 922 alsoincludes a battery management system (BMS) 928, a service disconnect906, and a plurality of contactors and pre-charge resistors showngenerally as electrical components 915. According to an exemplaryembodiment, the BMS 928 regulates the current, voltage, and/ortemperature of the electrochemical cells (not shown) in the batterymodules 924. Included with the service disconnect 906 is a servicedisconnect cover 907. According to an exemplary embodiment, the servicedisconnect 906 functions similarly to that of the service disconnectshown and described in FIGS. 41A and 41B (e.g., the service disconnectdisconnects the high voltage connections of the battery system in orderthat the battery system may be serviced).

The battery system 922 further includes high voltage connectors 910 thatare configured to connect the battery system 922 to an electrical systemof a vehicle. According to an exemplary embodiment, the high voltageconnectors include one negative polarity connector and one positivepolarity connector. The housing 920 also includes a grounding stud 911.

Although illustrated in FIGS. 46 and 47 as having a particular number ofbattery modules 924, it should be noted that according to otherexemplary embodiments, a different number and/or arrangement of batterymodules may be included in the battery system 922 depending on any of avariety of considerations (e.g., the desired power for the batterysystem, the available space within which the battery system must fit,etc.). The design and construction of the battery modules 924 allow formodular assembly (e.g., the modules may be quickly and efficientlymechanically, electrically, and/or thermally coupled to one another orwith other components of the battery system 922).

According to an exemplary embodiment, the battery modules 924 areprovided within a structure or housing 920. The housing 920, along witha cover (not shown) are configured to substantially surround theindividual battery modules 924 and other various components of thebattery system 922. According to an exemplary embodiment, a plurality ofsupport or frame members 916 are provided with the housing 920 (e.g., ona bottom portion of the housing) in order to couple the battery system922 to a vehicle (e.g., to a frame of a vehicle). According to otherexemplary embodiments, the frame members 916 may be otherwise providedand/or coupled to the housing 920 (e.g., such as on a top of the housingor side of the housing).

According to an exemplary embodiment, the battery system 922 includesconductive members (not shown) configured to conductively connect theindividual battery modules 924 to one another or to other components ofthe battery system 922 (such as, e.g., to the BMS 928 or electricalcomponents 915). As shown in FIG. 46, the conductive members may bepartially covered by a member shown as cover 914. The cover 914 isprovided to substantially insulate the conductive members.

The battery system 922 may also include a thermal management system toregulate the temperature of the individual cells (e.g., such as shown inFIG. 51) of the battery modules 924. To accomplish this, the batterysystem 922 includes a first manifold 902 and a second manifold 904configured to provide a heating and/or cooling fluid to the batterymodules 924. According to an exemplary embodiment, the manifold 902(inlet) is a supply manifold and the manifold 904 is return (outlet)manifold. According to another exemplary embodiment, the manifold 902 isa return manifold and the manifold 904 is a supply manifold. Accordingto an exemplary embodiment, an end of each of the manifolds 902, 904 isconnected to a fluid connection 900, 901 as shown in FIG. 46. Fluidconnections 900, 901 are configured to connect the manifolds 902, 904 toother components of the thermal management system (e.g., heat exchangerof the vehicle, etc.).

As shown in FIGS. 46 and 47, the manifolds 902, 904 include connectingmembers 903, 905 that are configured to connect the manifolds 902, 904to the heat exchangers (e.g., such as shown in FIG. 51) of theindividual battery modules 924. As seen in FIG. 47, each of theconnecting members 903 connects the manifold 902 to an opening 941 ofthe heat exchanger and each of the connecting members 905 connects themanifold 904 to the opening 942 of the heat exchanger. According to anexemplary embodiment, the connecting members 903, 905 each include aprojection (e.g., barb, protrusion, ridge, extension, etc.) configuredto aid in the retention of a hose clamp (not shown) on the connectingmembers 903, 905. The retention of the hose clamps on connecting members903, 905 aids in the ease and efficiency of assembling the manifolds902, 904 to the battery module 924.

As best seen in FIG. 47, the housing 920 is configured to allow easyaccess to the manifolds 902, 904 and the openings 941, 942 of the heatexchangers of the battery modules 924. For example, the housing 920includes a shallow side wall on the side of the openings 941, 942 of thebattery modules 924. Additionally, all of the fluid connections from themanifolds 902, 904 to the battery modules 924 are located along one sideof the battery system 922. This allows for ease and increased efficiencyof assembling the battery system 922. Likewise, substantially all of theelectric connections of the battery modules 924 are located along oneside of the battery system 922 (e.g., the side opposite of the manifoldconnections).

Referring now to FIGS. 48-59, the battery module 924 is discussed inmore detail according to an exemplary embodiment. The battery module 924includes an upper structure or housing 950 and a lower structure or tray960 that are configured to substantially cover and contain a pluralityof electrochemical cells 930 (e.g., as shown in FIG. 51). The housing950 includes a plurality of supports or ribs 951 provided on an externalsurface of the housing 950. The ribs 951 are configured to aid inenhancing the structural rigidity of the housing 950.

According to another exemplary embodiment, the housing 950 includes aplurality of apertures or openings 959 provided along an upper surfaceof the housing 950. The openings 959 are configured to allow fluids suchas condensation and/or gases and/or effluent (e.g., that may be ventedfrom the electrochemical cells 930) to exit the housing 950. The housing950 further includes apertures or openings 958 (e.g., as shown in FIG.53) to allow fluids to exit the housing 950. According to an exemplaryembodiment, the holes 958, 959 are provided throughout the housing 950at various locations to allow the fluid to exit the battery moduleregardless of the orientation the battery module 924 may be provided in(e.g., a vertical orientation, a horizontal orientation, etc.).

According to an exemplary embodiment, the housing 950 includes aplurality of members or elements shown as mounting members 953, 954. Asshown in FIGS. 48-51 and 59, the mounting members 953, 954 include atleast one opening or aperture configured to receive a fastener in orderto mount the battery module within a battery system (e.g., such as thebattery system 922 shown in FIGS. 46-47). According to an exemplaryembodiment, the battery module 924 includes a first set of mountingmembers 953, 954 at a first end of the battery module 924 and a secondset of mounting members 953, 954 at a second end of the battery module924.

According to an exemplary embodiment, a portion of the mounting members953, 954 may be configured in a generally horizontal orientation (e.g.,such as the mounting members 953) and another portion of the mountingmembers 953, 954 may be provided in a substantial vertical orientation(e.g., such as mounting members 954). According to other exemplaryembodiments, the mounting members 953, 954 may be provided in otherorientations or configurations.

According to an exemplary embodiment, a portion of the mounting members953, 954 may be provided as a single component (e.g., a single unitarymember). For example, as shown in FIG. 48, one of the mounting members954 is provided as a single member with one of the mounting members 953.According to other exemplary embodiments, the mounting members 953, 954may be provided as separate components and later coupled (e.g., welded)together. Having the various configurations and orientations of themounting members 953, 954 allows the battery module 924 to be mountedwithin a battery system in various configurations. As one of ordinaryskill in the art would readily understand, not all of the mountingmembers 953, 954 need to be used in every mounting configuration of thebattery module 924 (e.g., some of the apertures or holes included withinthe mounting members 953, 954 may not be utilized in every mountingconfiguration).

Referring now to FIG. 49, the battery module 924 is shown to include acover 990 that is configured to substantially cover a top portion of thebattery module 924. Included at the top portion of the battery module924 is a bus bar assembly 970, a traceboard 980, and a cell supervisorycontroller (CSC) 982. According to an exemplary embodiment, the cover990 may be fastened to the housing 950 by a plurality of snap-fitfeatures. For example, the cover 990 may include a plurality ofprojections shown as snap-hooks 994 that are configured to be receivedin a slot or opening 996 (e.g., as shown in FIG. 59). A ridge or lip ofthe snap-hooks 994 engages a ledge 997 once the snap-hooks 994 passthrough the openings 996. According to an exemplary embodiment, thecover 990 may include the openings 996 and the housing 950 may includethe snap-hooks 994. According to other exemplary embodiments, the cover990 may be otherwise coupled to the housing 950 (e.g., with fasteners,glue, etc.).

According to an exemplary embodiment, the bus bar assembly 970 includesa plurality of bus bars 973 provided on a first layer or substrate 971(e.g., a plastic or film such as Mylar®). According to anotherembodiment, a second layer (not shown) may be provided to sandwich theplurality of bus bars 973 between the first layer 971 and the secondlayer. As shown in FIG. 49, each of the plurality of bus bars 973includes an aperture or opening 974 provided at each end of each of thebus bars 973. These openings 974 are configured to receive a fastener inorder to couple the bus bar 973 to a terminal (e.g., such as a positiveterminal 932 or a negative terminal 934 as shown in FIG. 49).

According to an exemplary embodiment, the traceboard 980 includes aplurality of flexible contacts 984 (e.g., as shown in FIGS. 55 and 59).The flexible contacts 984 may be similar to the flexible contacts 584 asshown and described in FIG. 33A. According to an exemplary embodiment,the flexible contacts 984 may be connected to connectors 983 (e.g., asshown in FIGS. 55 and 59) by a plurality of conductive lines or wires(not shown). According to an exemplary embodiment, the traceboard 980may also include a plurality of various sensors (e.g., voltage sensors,temperature sensors, etc.) and other electrical components.

According to an exemplary embodiment, the CSC 982 may be mechanicallycoupled (e.g., by fasteners) to the traceboard 980. Additionally, theCSC 982 may be electrically coupled with the traceboard 980 by a cableor connector (not shown). According to an exemplary embodiment, the CSC982 is configured to monitor and/or regulate the temperature, current,and/or voltage of electrochemical cells 930 (e.g., as shown in FIG. 51).

Referring now to FIG. 51, a plurality of electrochemical cells 930 areprovided within the housing 950. According to an exemplary embodiment,the electrochemical cells 930 are generally cylindrical lithium-ioncells configured to store an electrical charge. According to otherexemplary embodiments, the cells may be nickel-metal-hydride cells,lithium polymer cells, etc., or other types of electrochemical cells nowknown or hereafter developed. According to other exemplary embodiments,the electrochemical cells 930 could have other physical configurations(e.g., oval, prismatic, polygonal, etc.). The capacity, size, design,and other features of the electrochemical cells 930 may also differ fromthose shown according to other exemplary embodiments.

According to an exemplary embodiment, the electrochemical cells 930include one positive terminal 932 and one negative terminal 934 at afirst end of the cell 930 (e.g., as shown in FIG. 49). Theelectrochemical cells 930 also include a vent 936 at a second end of thecell 930 opposite of the first end. The vent 936 is configured to breakaway (i.e., deploy) from the cell 930 once the internal pressure of thecell 930 reaches a predetermined level. When the vent 936 is deployed(i.e., broken away from the cell) gases and/or effluent are allowed tobe released from the cell 930. According to an exemplary embodiment, thevent 936 is a circular vent disk located at the bottom of the cell 930.According to other exemplary embodiments, the cell 930 may havedifferent terminal and/or vent configurations (e.g., the positiveterminal may be located on one end of the cell 930 and the negativeterminal may be located on the opposite end of the cell 930).

According to an exemplary embodiment, the battery housing 950 isconfigured to receive two rows of six electrochemical cells 930 each fora total of twelve electrochemical cells 930. Although illustrated inFIG. 51 as having a particular number of electrochemical cells 930, itshould be noted that according to other exemplary embodiments, adifferent number and/or arrangement of electrochemical cells 930 may beused depending on any of a variety of considerations (e.g., the desiredpower for the battery module 924, the available space within which thebattery module 924 must fit, etc.).

According to an exemplary embodiment, the tray 960 is provided at alower end of the housing 950. According to an exemplary embodiment, thetray 960 is coupled to the bottom portion of the housing 950 by asnap-fit configuration. According to other various exemplaryembodiments, the tray 960 may be otherwise coupled to the housing 950(e.g., with fasteners, adhesives, welding, etc.). As shown in FIGS.50-51, the tray 960 includes a member shown as a snap-hook 966 that isconfigured to be received within an aperture or opening 952 provided inthe housing 950 (e.g., such as shown in FIGS. 52-53).

According to an exemplary embodiment, the tray 960 includes a feature orelement shown as an alignment tab 967 configured to aid in the insertionof the tray into the bottom portion of the housing 950. As shown in thefigures, the alignment tab 967 extends to a height greater than that ofthe snap-hook 966. According to an exemplary embodiment, the snap-hook966 and alignment tab 967 may be provided together as a single componentwith the tray 960. According to other exemplary embodiments, thesnap-hooks 966 and the alignment tabs 967 may be provided separatelyfrom one another.

According to an exemplary embodiment, the tray 960 includes a pluralityof openings or sockets that are configured to receive a lower end of thecells 930. The sockets may include an aperture or opening 961 that isconfigured to coincide with the vent 936 of the cells 930. The tray 960further includes a member or wall 964 configured to aid in thepositioning and/or retention of the lower end of the cells 930.According to an exemplary embodiment, the tray 960 also includes amember or plurality of projections 968. The plurality of projections 968may aid in the positioning and/or retention of the cells 930. Accordingto another exemplary embodiment, the plurality of projections 968 mayalso aid in positioning of a heat exchanger 940 within the housing 950.

According to an exemplary embodiment, the tray 960 is configured toreceive a member shown as an inlay 962. The inlay 962 comprises aplurality of conjoined rings. Each ring is connected to another ring bya connecting member 963 (e.g., as shown in FIG. 50). Additionally, eachring may have an internal diameter 969 that generally corresponds withthe opening 961 of the sockets of the tray 960. According to anexemplary embodiment, the tray 960 may have an opening or a cut-out 965provided in the walls 964 of the tray to receive the connecting members963 of the inlay 962.

According to an exemplary embodiment, the inlay 962 may be constructedof a flexible material such as EPDM foam (or any other suitablematerial). The inlays 962 are configured to take up any dimensionaltolerance variation of the battery module 924 during assembly.Additionally, the inlay 962 may aid in isolating the electrochemicalcells 930 from vibrations (e.g., during operation of the vehicle).

According to an exemplary embodiment, the tray 960 includes a feature orelement shown as a wall 937. As shown in FIG. 51, the wall 937 generallycoincides with the inner diameter 961 of the sockets of the tray 960.The walls 937 of each of the sockets of the tray 960 provide a ventopening feature for the vent 936. An example and description of a ventopening feature may be found in International Application No.PCT/US2009/053697, filed Aug. 13, 2009, the entire disclosure of whichis incorporated herein by reference.

According to an exemplary embodiment, the battery module 924 alsoincludes a heat exchanger 940 that is configured to be provided inbetween the rows of electrochemical cells 930 as shown in FIG. 51. Asshown in FIGS. 54A-54C, the heat exchanger 940 includes a first opening941 and a second opening 942. According to one exemplary embodiment, thefirst opening 941 is configured to be an inlet while the second opening942 is configured to be an outlet. According to another exemplaryembodiment, the opening 942 may be configured to be an inlet while theopening 941 may be configured to be an outlet.

According to an exemplary embodiment, a fluid (a heating or coolingfluid, such as, e.g., a refrigerant, water, water/glycol mixture, etc.)flows through the heat exchanger 940 through passages 948 that areseparated by a gap 949. As shown in FIG. 54A, the fluid follows the pathillustrated by arrows 947 when the opening 941 is an inlet and theopening 942 is an outlet. When the opening 942 is an inlet and theopening 941 is an outlet, the flow of the fluid through the heatexchanger 940 would be in the opposite direction.

According to an exemplary embodiment, the flow of the fluid inside theheat exchanger 940 may be in a zig-zag motion (e.g., as shown by arrow947 in FIG. 54A), but may vary according to other exemplary embodiments.According to one exemplary embodiment, the discrete path 548 may beseparated by a gap 549 (or, alternatively, there may be solid materialbetween the paths rather than a gap to separate the various parts of thewinding path from each other) to form multiple segments of the path 548.

In this manner, the fluid may be routed through the heat exchanger 940such that it passes past each of the cells multiple times as it zig-zagsthrough the heat exchanger 940. Similar to the fluid flow within theheat exchanger described with respect to FIG. 20, the fluid flow throughthe heat exchanger is divided into multiple segments that are separatedfrom each other, although instead of flowing in a single directionbetween an inlet or an outlet, the fluid in the heat exchanger 940reverses its flow direction as it transitions between one segment of thefluid flow path and the adjacent segment of the fluid flow path.

As shown in FIGS. 54A-54C, both the opening 941 and opening 942 arelocated on the same end of the heat exchanger 940. This allows for theconnections (e.g., from manifolds such as shown in FIGS. 46 and 47) tothe openings 941, 942 to be made on the same side of the battery module.Additionally, having openings 941, 942 on the same side of the heatexchanger 940 allows for an even number of segments to be provided inthe heat exchanger 940. For example, the heat exchanger 940 is providedwith four segments, with the fluid flowing past each of the cells 930 aneven number of times. Having an even number of segments (and having aneven number of times the fluid flows past a specific cell 930) allowsfor more even cooling and/or heating of the cells.

For example, during cooling of the cells 930, the fluid enters the heatexchanger 940 at a cool temperature. The temperature of the fluid willwarm as it passes the cells 930 and flows along the flow path 947. Asthe fluid warms, there is less heat transfer out from the cells 930.However, by having an even number of segments as shown in FIG. 54A,cooling is evened out among the cells 930 by having the now warm fluidflow past the cells near the inlet as the fluid exits the opening 942.

As shown in FIG. 54B, the heat exchanger 940 includes an externalsurface 943 that is shaped to coincide with an external surface 938 ofthe electrochemical cells 930. As such, the external surface 943 of theheat exchanger 940 includes curved sections represented by referencenumbers 944 (a valley, trough, etc.) and 945 (a peak, high point, etc.).According to one exemplary embodiment, the design of the heat exchanger940 is configured to provide an angled contact along each of theelectrochemical cells 930. According to an exemplary embodiment, theangled contact for each electrochemical cell 930 is substantially thesame as that of the rest of the electrochemical cells 930. However,according to other exemplary embodiments, the angle of contacts may varyamong the electrochemical cells 930 (e.g., to more evenly provide heattransfer to/from the cells).

According to an exemplary embodiment, the heat exchanger 940 may be madefrom a blow molding process, an injection molding process, or othersuitable process. According to an exemplary embodiment, the wallthickness of the heat exchanger 940 is between approximately 0.6millimeters and 1.0 millimeters, but may have a greater or lesser wallthickness according to other exemplary embodiments. According to oneexemplary embodiment, the heat exchanger 940 is semi-flexible andconfigured to conform to the outside of the electrochemical cells 930.For example, the heat exchanger 940 may expand under a slight (e.g.,between approximately 5-10 psi) fluid pressure such that the heatexchanger 940 expands so that the external surface 943 makes contactwith and/or conforms to the external surface 938 of the electrochemicalcells 930.

According to an exemplary embodiment, the heat exchanger 940 may be madeof a polymeric material (e.g., polypropylene) or other suitable materialthat allows for heat conduction to/from the cells 930 (e.g., anelectrically insulative and thermally conductive material). According toanother exemplary embodiment, the heat exchanger 940 may be made of ametallic material (e.g., aluminum or aluminum alloy) or other suitablematerial (e.g., when the external surface of the cells 930 are notelectrically charged (e.g., can neutral) or a separate electricallyinsulative and thermally conductive material is provided between thecells and the heat exchanger). According to another exemplaryembodiment, the heat exchanger 940 may be made of a ceramic material orother suitable material.

Referring now to FIGS. 55-58D, a member shown as a bracket 9000 isprovided on an end of the battery module 924. According to one exemplaryembodiment, two brackets 9000 are provided with each battery module 924;however, the battery module 924 may include a greater or lesser numberof brackets 9000 according to other exemplary embodiments. Each bracket9000 is configured to retain (e.g., hold, clasp, clinch, clutch, grasp,keep, etc.) a temperature sensor 9020 in contact with an electrochemicalcell 930. According to an exemplary embodiment, the placement of thetemperature sensor 9020 is approximately at a midpoint of theelectrochemical cell 930. According to other exemplary embodiments, theplacement of the temperature sensor 9020 may be higher or lower than themidpoint of the electrochemical cell 930.

Bracket 9000 includes a main body 9001 having a first end 9002 and asecond end forming a plurality of hooks 9003. According to one exemplaryembodiment, the first end 9002 is configured to be placed within a holeor opening 957 (see, e.g., FIG. 55) located in a flange of the housing950 of the battery module 924, while the hooks 9003 are configured toengage a slot or opening 956 located in the housing 950 of the batterymodule 924. As shown in FIGS. 55-58D, the bracket 9000 includes twohooks 9003; however, according to other exemplary embodiments, thebracket 9000 may include a greater or lesser number of hooks 9003.

The bracket 9000 further includes a feature or element shown as aretention device 9010. The retention device 9010 includes a pair ofmembers or arms 9012 coupled to a body portion 9016. As shown in FIG.58D, the arms 9012 oppose one another. Each arm 9012 includes an innersurface 9014. As shown in FIG. 58D, the inner surface 9014 is curvedsuch as to correspond to the shape of the temperature sensor 9020 (e.g.,as shown in FIG. 57). According to other exemplary embodiments, theretention device 9010 (including the arms 9012 and the body portion9016) may have other configurations.

According to an exemplary embodiment, the bracket 9000 is formed from asemi-flexible material such as a plastic material (e.g., Nylon, etc.) orother suitable material. As seen best in FIG. 58C, the bracket 9000 hasa curvature in regards to the first end 9002 and the hooks 9003.However, once the bracket 9000 is installed on the battery module 924,the bracket 9000 is in a substantially straight or uncurved position,creating a force to hold or maintain the temperature sensor 9020 incontact with the electrochemical cell 930.

As shown in FIG. 57, the temperature sensor 9020 includes electricalcontacts 9022. The contacts 9022 are configured to be connected (e.g.,by wires) to another part of the battery module 924 (e.g., the CSC) inorder to read and monitor the temperature of the electrochemical cell930.

Referring now to FIG. 59, a portion of the battery module 924 is shownaccording to an exemplary embodiment. The battery module 924 is shown toinclude a feature shown as a projection 955 that extends out from thehousing 950. As shown in FIG. 59, the battery module 924 includes twosuch projections 955. Each projection 955 is configured to receive aconductive member 975 that at one end is conductively connected to aterminal (such as shown in FIG. 51) of an electrochemical cell 930.

Each conductive member 975 includes an aperture or opening 976 at eachend of the conductive member 975. One of the openings 976 is configuredto receive a fastener (such as fastener 989) in order to couple theconductive member 975 to the terminal of an electrochemical cell 930.The other opening 976 of the conductive member 975 is configured toconnect the battery module 924 to another battery module 924 (e.g., suchas shown in FIG. 46) or to another component of the battery system 922.The projections 955 offer rigid support to the conductive member 975such that loads or forces imposed on the conductive member 975 aretransferred to the projections 955 and not to the electrochemical cell930 (or to the terminals of the electrochemical cell 930) that theconductive member 975 is connected to.

According to an exemplary embodiment, the projections 955 areconstructed from a material similar to or the same as the housing 950(e.g., such as a polyethylene, polypropylene, etc.). According toanother exemplary embodiment, the projections 955 may have a shape orform substantially similar to that of the end of the conductive members975.

Referring now to FIGS. 60-64D, a battery system 1022 is shown accordingto an exemplary embodiment. The battery system 1022 includes a pluralityof battery modules 1024. Although not specifically shown, each batterymodule 1024 includes a plurality of electrochemical cells or batteries(e.g., lithium-ion cells, nickel-metal-hydride cells, lithium polymercells, etc., or other types of electrochemical cells now known orhereafter developed). According to an exemplary embodiment, theelectrochemical cells are generally cylindrical lithium-ion cellsconfigured to store an electrical charge. According to other exemplaryembodiments, cells could have other physical configurations (e.g., oval,prismatic, polygonal, etc.). The capacity, size, design, and otherfeatures of the cells may also differ from those shown according toother exemplary embodiments.

Although illustrated in FIGS. 60-64D as having a particular number ofbattery modules 1024 (i.e., two rows of four modules for a total ofeight modules), which in turn include a particular number ofelectrochemical cells (i.e., two rows of five cells per module for atotal of 10 electrochemical cells per module and 80 electrochemicalcells per battery system), it should be noted that according to otherexemplary embodiments, a different number and/or arrangement of modulesand/or electrochemical cells may be used depending on any of a varietyof considerations (e.g., the desired power for the battery system, theavailable space within which the battery module and/or battery systemmust fit, etc.).

According to the exemplary embodiment shown in FIGS. 60-64D, the batterysystem 1022 includes a thermal management system 1110. According to anexemplary embodiment, the thermal management system 1110 is configuredas a stand-alone modular system. The thermal management system 1110 maybe sized specifically for the application that the battery system 1022is being used in and scalable to the specific requirements of theapplication. For example, the various components of the thermalmanagement system 1110 may be swapped out to meet the specificrequirements of the application.

The thermal management system 1110 is a complete stand-alone system toprovide cooling and/or heating to the battery system 1022. The thermalmanagement system 1110 does not need to be connected to anyheating/cooling system of the vehicle it is placed in. Additionally, themodular thermal management system 1110 may be removed and/or reattachedto the battery system 1022 as needed (e.g., to swap out components, toreattach a smaller or larger rated thermal management system, etc.).According to an exemplary embodiment, the thermal management system 1110is coupled to the battery system 1022 with a plurality of snap-fitconnections or fasteners (not shown).

As shown in FIG. 64C, the thermal management system 1110 provides twoclosed loop cooling circuits to the battery system 1022 (i.e., a singleclosed loop cooling system for each row of battery modules 1024). Itshould be noted that FIGS. 60-64C show a cooling system; however, thethermal management system 1110 may also provide heating to the batterysystem 1022 if needed.

According to an exemplary embodiment, as shown in FIG. 64C, the thermalmanagement system 1110 includes a compressor 1120, a pump 1130, aradiator/condenser 1140 for each row of battery modules 1024, and a fan(not shown) located in a fan housing 1150. Refrigerant used in thethermal management system 1110 may be Freon (e.g., R134a), water, CO₂,or other suitable fluid. The thermal management fluid (i.e., coolingfluid) that is routed to the battery modules 1024 (e.g., via manifolds)is preferably a water-glycol mixture (e.g., 50/50 mixture) but may varyaccording to various other embodiments.

The thermal management system 1110 further includes a cooling line 1102(supply line) coming from the pump 1130 and supplies cooled coolingfluid to a supply manifold 1002 located external to the row of batterymodules 1024. As seen in FIG. 63, cooling lines 1141 connect to manifoldconnections 1003 of the supply manifold 1002 and the battery module 1024(e.g., to a heat exchanger located inside the battery module 1024). Thecooling fluid is routed through the individual battery modules 1024 tocool the electrochemical cells 330.

According to an exemplary embodiment, the cooling fluid is routed aroundthe outside of the battery module 1024 to cool the cells located insidethe battery module 1024. According to another exemplary embodiment, thecooling fluid is routed through (in between) the two rows of cells.According to other various embodiments, the cooling fluid may be routedthrough the battery module 1024 in any configuration that is necessaryto cool the electrochemical cells inside the battery module 1024.

Referring again to FIG. 64C, cooling lines 1142 route the cooling fluidexiting the battery modules 1024 to a return manifold 1004. The returnmanifold 1004 is connected to the radiator/condenser 1140 by a returnline 1104 to remove heat from the now warmed cooling fluid. According toanother exemplary embodiment, the flow of the cooling fluid may bereversed (e.g., the return manifold and return lines would become supplymanifold and supply lines, while the supply manifold and supply lineswould become return manifold and return lines) such that the coolingfluid flows inside to outside the battery system 1022.

As shown in FIG. 64C, the thermal management system 1110 providesseparate cooling to the individual rows of battery modules 1024. This isintended to aid in balancing the temperatures of the electrochemicalcells so that the temperatures throughout the entire battery system 1022are as even as possible. According to other various exemplaryembodiments, there may be only a single cooling loop for the entirebattery system 1022.

Referring to FIG. 64C, each battery module 1024 includes its own cellsupervisory controller (CSC) 1082 to monitor cell voltage and ortemperature. The CSC 1082 may balance the cells if necessary (e.g., evenout the individual cell voltages and/or temperatures), as well asprovide redundant protection for overvoltage, undervoltage, andovertemperature conditions. According to an exemplary embodiment, theCSC 1082 is mounted on and electrically connected to a traceboard 1080(e.g., printed circuit board). The traceboard is configured toelectrically connect the electrochemical cells to the CSC 1082. Thebattery system 1022 may also include a battery management system (notshown) that monitors and/or regulates the battery modules 1024 andelectrochemical cells.

The battery system 1022 may also include a number of openings or windows1011 in a cover 1010 or housing 1020 to allow a user to view theinternal components of the battery system 1022 (e.g., as shown in FIGS.60-63). Alternatively, the openings may be replaced with a single opaqueor solid cover.

The battery module 1024 also includes a plurality of openings or airvents 1112, 1113 to allow air to enter or exit the battery system 1022(e.g., as shown in FIGS. 61-62) to be used by the thermal managementsystem 1110 (e.g., air may be blown across the radiator 1140). Air mayenter the air openings 1112 of the battery system 1022 from theenvironment surrounding the battery system 1022 (e.g., air contained inthe rear of the vehicle or a trunk of the vehicle may enter the batterysystem through the air openings when the battery system is placed in therear of a vehicle or the trunk of a vehicle). Alternatively, air may berouted to the battery system 1022 via ductwork connecting the airopenings 1112 and the source of the air (e.g., ducts connecting the airopenings to the cabin of the vehicle, to outside of the vehicle, etc.).Air may then exit the battery system 1022 through the openings 1113.According to another exemplary embodiment, air may enter the openings1113 and exit the openings 1112.

Referring now to FIG. 64D, the battery system 1022 also includes athree-position switch shown as an on/off/service disconnect switch 1006.The switch 1006 includes a member or handle 1007 and is configured toallow a user to choose between different modes of operation of thebattery system 1022. For example, when the switch 1006 is set in the onposition, the battery is capable of supplying electrical power to thevehicle. When the switch 1006 is set to the off position, the batterysystem 1022 is off (i.e., not supplying power). The off position may beused, for example, when shipping the battery system 1022 prior toinstallation in the vehicle.

The third position, the service position, is selected by a user whenservicing the battery system 1022. Activating the switch 1006 to theservice position disconnects the first row of battery modules 1024 fromthe second row of battery modules 1024, thus lowering the overallvoltage potential of the battery system 1022 by half The serviceposition also allows the battery cover 1010 of the battery system to betaken off, allowing the user to service the battery system 1022. Thecover 1010 may not be taken off when the switch 1006 is in either the onor the off position.

Referring now to FIGS. 65-68, a battery system 1222 is shown accordingto another exemplary embodiment. The battery system 1222 shown in FIGS.65-68 is conceptually similar to the battery system 1022 shown in FIGS.60-64D.

Referring to FIGS. 65-68, the battery system 1222 is shown to include aplurality of battery modules 1224. Although not specifically shown, eachbattery module 1224 includes a plurality of electrochemical cells orbatteries (e.g., lithium-ion cells, nickel-metal-hydride cells, lithiumpolymer cells, etc., or other types of electrochemical cells now knownor hereafter developed). According to an exemplary embodiment, theelectrochemical cells are generally cylindrical lithium-ion cellsconfigured to store an electrical charge. According to other exemplaryembodiments, cells could have other physical configurations (e.g., oval,prismatic, polygonal, etc.). The capacity, size, design, and otherfeatures of the cells may also differ from those shown according toother exemplary embodiments.

Although illustrated in FIGS. 65-68 as having a particular number ofbattery modules 1224 (i.e., two rows of four modules for a total ofeight modules), which in turn include a particular number ofelectrochemical cells (i.e., two rows of five cells per module for atotal of 10 electrochemical cells per module and 80 electrochemicalcells per battery system), it should be noted that according to otherexemplary embodiments, a different number and/or arrangement of modulesand/or electrochemical cells may be used depending on any of a varietyof considerations (e.g., the desired power for the battery system, theavailable space within which the battery module and/or battery systemmust fit, etc.).

According to the exemplary embodiment as shown in FIGS. 65-68, thebattery system 1222 includes a thermal management system 1310. Accordingto an exemplary embodiment, the thermal management system 1310 isconfigured as a stand-alone modular system. The thermal managementsystem 1310 may be sized specifically for the application the batterysystem 1222 is being used in and scalable to the specific requirementsof the application. For example, the various components of the thermalmanagement system 1310 may be swapped out to meet the specificrequirements of the application.

The thermal management system 1310 is a complete stand-alone system toprovide cooling and or heating to the battery system 1222. That is, thethermal management system 1310 does not need to be connected to anyheating/cooling system of the vehicle it is placed in. Additionally, themodular thermal management system 1310 may be removed and/or reattachedto the battery system 1222 as needed (e.g., to swap out components, toreattach a smaller or larger rated thermal management system, etc.).According to an exemplary embodiment, the thermal management system 1310is coupled to the battery system 1222 with a plurality of snap-fitconnections or fasteners (not shown).

As shown in FIGS. 65-68, the thermal management system 1310 provides twoclosed loop cooling circuits to the battery system 1222 (i.e., a singleclosed loop cooling system for each row of battery modules 1224). Itshould be noted that FIGS. 60-64C show a cooling system; however, thethermal management system 1310 may also provide heating to the batterysystem 1222 if needed. The thermal management system 1310 may include acompressor, a pump, a radiator/condenser for each row of batterymodules, and a fan located in a fan housing. Refrigerant used in thethermal management system 1310 may be Freon (e.g., R134a), water, orCO₂. The thermal management fluid (i.e., cooling fluid) that is routedto the battery modules 1224 (e.g., via manifolds) is preferably awater-glycol mixture (e.g., 50/50 mixture), but may vary according tovarious other embodiments.

The thermal management system 1310 further includes a cooling line orsupply line (not shown) coming from the pump and supplies cooled coolingfluid to a supply manifold 1202 located external the row of batterymodules 1224. As seen in FIGS. 66 and 67, cooling lines 1341 connect tomanifold connections of the supply manifold 1202 and the battery module1224. The cooling fluid is routed through the individual battery modules1224 to cool the electrochemical cells. According to an exemplaryembodiment, the cooling fluid is routed around the outside of thebattery module 1224 to cool the cells located inside the battery module1224. According to another exemplary embodiment, the cooling fluid isrouted through (in between) the two rows of cells. According to othervarious embodiments, the cooling fluid may be routed through the batterymodule 1224 in any configuration that is necessary to cool theelectrochemical cells inside the battery module 1224.

Referring again to FIGS. 66 and 67, cooling lines 1342 route the coolingfluid exiting the battery module 1224 to a return manifold 1204. Thereturn manifold 1204 is connected to the radiator/condenser (not shown)by a return line (not shown) to remove heat from the now warmed coolingfluid. According to another exemplary embodiment, the flow of thecooling fluid may be reversed (e.g., the return manifold and returnlines would become supply manifold and supply lines, while the supplymanifold and supply lines would become return manifold and return lines)such that the cooling fluid flows inside to outside the battery system1222.

The thermal management system 1310 may provide separate cooling to theindividual rows of battery modules 1224. This is intended to aid inbalancing the temperatures of the electrochemical cells so that thetemperatures throughout the entire battery system 1222 are as even aspossible. According to other various exemplary embodiments, there may beonly a single cooling loop for the entire battery system 1222.

Referring to FIGS. 66-68, each battery module 1224 includes its own cellsupervisory controller (CSC) 1282 to monitor cell voltage and/ortemperature. The CSC 1282 may balance the cells if necessary (e.g., evenout the individual cell voltages and/or temperatures), as well asprovide redundant protection for overvoltage, undervoltage, andovertemperature conditions. The battery system also includes a batterydisconnect unit (BDU) 1226 that may include a battery management system(not shown) to monitor and/or regulate the battery modules 1224 andelectrochemical cells.

The battery system 1222 may also include a number of openings ortransparent windows 1211 located in a cover 1210 to allow a user to viewthe internal components of the battery system (e.g., as shown in FIG.65). Alternatively, the openings may be replaced with an opaque or solidcover. The battery system 1222 also includes a plurality of openings orair vents 1212 to allow air to enter the battery system 1222 (e.g., asshown in FIGS. 61-62) to be used by the thermal management system 1310(e.g., air may be blown across the radiator). Air may enter the airopenings 1212 of the battery system 1222 from the environmentsurrounding the battery system 1222 (e.g., air contained in the rear ofthe vehicle or a trunk of the vehicle may enter the battery system 1222through the air openings when the battery system is placed in the rearof a vehicle or the trunk of a vehicle). Alternatively, air may berouted to the battery system via ductwork connecting the air openingsand the source of the air (e.g., ducts connecting the air openings tothe cabin of the vehicle, to outside of the vehicle, etc.).

Referring now to FIGS. 69A-69C, various cover and terminal assemblydesigns are shown for a cell according to various exemplary embodiments.A first cover and terminal assembly design includes a cover 1410 havinga first terminal 1420 and a second terminal 1430 attached thereto.According to an exemplary embodiment, the terminal 1430 is electricallyinsulated from the cover 1410 by a member shown as an insulator 1432.Coupled to the terminals are bus bars 1440 (e.g., by a fastener 1450).

Also shown in FIGS. 69A-69C is a traceboard 1460 having aperturestherein that are configured to align with the terminals 1420, 1430.According to an exemplary embodiment, a flexible contact 1450 may beprovided in the apertures. Also shown is a CSC 1470 configured tomonitor and/or regulate the various cells.

A proposed design (having reference numbers in the 1500's) is shownaccording to an exemplary embodiment. According to an exemplaryembodiment, the proposed design includes a cover 1510 having a firstterminal 1520 and a second terminal 1530. According to an exemplaryembodiment, the terminal 1530 may be electrically insulated from thecover 1510 by a member shown as insulator 1532.

As shown in FIG. 69C, the cover 1510 is shown coupled to the bus bar1440. According to an exemplary embodiment, the terminals 1520, 1530 arethreaded studs having nuts 1534 threaded onto them in order to couplethe terminals 1520, 1530 to the bus bar 1440.

As can be seen in FIG. 69A-69C, the proposed design offers a number ofadvantageous features. For instance, in the proposed design, the coverand terminal assembly are formed substantially from a stamping process.Using a stamping process saves time and cost over a more traditionalforming process (e.g., machining separate components and then assemblingthem together).

Additionally, the weight and material used in the proposed design isreduced. For instance, the diameter and the height of the terminals arereduced in the proposed design. Additionally, the terminals 1520, 1530in the proposed design are threaded studs, allowing for more efficientpackaging and assembly.

According to an exemplary embodiment, a battery module is providedhaving modular construction such that the battery module may bemodularly assembled with other battery modules into a battery system.The battery module includes a plurality of electrochemical cellsprovided in two rows and a cooling element provided in between the tworows of cells. The cells and the cooling element are enclosed orsurrounded by a housing, a bottom, and a cover. The battery module alsoincludes a bus bar assembly to electrically couple the cells to oneanother and a cell supervisory controller configured to monitor andregulate the cells.

According to an exemplary embodiment, a battery system includes aplurality of battery modules and a thermal management system configuredto provide heating and/or cooling to the battery modules. Other featuresof the battery system may include a battery on/off/service disconnectswitch, air vents or openings, and a battery management system. Thebattery modules are arranged in two rows containing four battery modulesin each row. The battery modules may each include a plurality ofelectrochemical cells electrically connected together with bus bars.Each battery module may also include a cell supervisory controller tomonitor and regulate the electrochemical cells. The thermal managementsystem is configured as a stand-alone thermal management system and isconfigured to provide closed loop cooling and/or heating to eachindividual row of battery modules. The thermal management system ismodular in that it may be scaled up or down dependent upon therequirements of the application. The thermal management system may alsoinclude a compressor, a pump, a fan, a fan housing, and a separateradiator/condenser for each closed loop. The thermal management fluid issupplied to the battery modules through a manifold having individualsupply lines to each individual battery module. The thermal managementfluid returns to the radiator/condenser for that row of battery modulesthrough a return manifold.

According to another exemplary embodiment the battery system includes aplurality of battery modules arranged side-by-side within the housing.The housing includes openings to provide a cooling or heating fluid tothe individual battery modules. The openings are connected to theindividual battery modules through a plurality of manifolds and supplyand return lines. The battery modules are arranged side-by-side so thatthey are nested next to each other to provide an efficient use of spacewithin the battery system.

As utilized herein, the terms “approximately,” “about,” “substantially,”and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

It is important to note that the construction and arrangement of thebattery modules and/or systems as shown in the various exemplaryembodiments is illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Forexample, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of any processor method steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay also be made in the design, operating conditions and arrangement ofthe various exemplary embodiments without departing from the scope ofthe present invention.

1. A battery module comprising: a plurality of electrochemical cellsarranged in a first row and a second row offset from the first row; anda heat exchanger configured to allow a fluid to flow therethrough, theheat exchanger disposed between the first and second rows of cells andhaving a shape that is complementary to the cells in the first andsecond rows of cells so that an external surface of the heat exchangercontacts a portion of each of the plurality of electrochemical cells;and wherein the heat exchanger is configured to route the fluid betweenan inlet and an outlet such that a path of the fluid flow includes aplurality of adjacent fluid flow segments.
 2. The battery module ofclaim 1, wherein the fluid flows through the adjacent fluid flowsegments in a first direction from a first end of the heat exchanger toa second end of the heat exchanger along a length of the battery module.3. The battery module of claim 1, wherein the fluid flows through afirst fluid flow segment in a first direction from a first end of theheat exchanger to a second end of the heat exchanger and flows throughan adjacent fluid flow segment in a second direction different than thefirst direction.
 4. The battery module of claim 3, wherein the inlet isadjacent the first end of the heat exchanger and the outlet is adjacentthe second end of the heat exchanger.
 5. The battery module of claim 3,wherein the inlet and the outlet are adjacent the first end of the heatexchanger.
 6. The battery module of claim 1, further comprising ahousing configured to receive the plurality of electrochemical cells andhaving an internal surface configured to contact a portion of theexterior surface of each of the plurality of electrochemical cells, thehousing having an external surface substantially complementary to theinternal surface of the housing.
 7. The battery module of claim 6,wherein the external surface of the housing is configured to nest withan external surface of a housing of an adjacent battery module within abattery system to provide an efficient use of space within the batterysystem.
 8. The battery module of claim 1, wherein a top portion of thehousing comprises a plurality of openings having a first diameter and aplurality of openings having a second diameter, wherein each of theplurality of openings having the first diameter are configured toreceive a first terminal of one of the electrochemical cells and each ofthe plurality of openings having the second diameter are configured toreceive a second terminal of one of the plurality of electrochemicalcells, wherein the first diameter is different from the second diametersuch that the plurality of electrochemical cells are provided within thehousing in the proper configuration.
 9. The battery module of claim 1,further comprising a structure configured to be coupled to a bottomportion of the housing, the structure comprising a plurality of featuresconfigured to aid in properly positioning each of the electrochemicalcells within the battery module.
 10. The battery module of claim 1,further comprising a bracket configured to retain a sensor in contactwith one of the plurality of electrochemical cells, the bracketcomprising a pair of opposing arms configured to retain the sensor andhaving a first end configured to engage a first opening in the housingand a second end configured to engage a second opening in the housing.11. The battery module of claim 1, further comprising a plurality ofmounting members at a first end of the housing, at least one of themounting members arranged orthogonally with respect to the othermounting members to provide multiple configurations in which to mountthe battery module within a battery system.
 12. The battery module ofclaim 11, further comprising at least one aperture within each of theplurality of mounting members.
 13. A battery module comprising: a heatexchanger provided between a first row of electrochemical cells and asecond row of electrochemical cells arranged offset from the first rowof cells, the heat exchanger having an external surface in contact withat least a portion of each of the electrochemical cells, wherein theheat exchanger is configured to allow a fluid to flow therethroughbetween an inlet and an outlet such that a path of the fluid flowincludes a plurality of adjacent fluid flow segments.
 14. The batterymodule of claim 13, wherein the fluid flows through the adjacent fluidflow segments in a first direction from a first end of the heatexchanger to a second end of the heat exchanger along a length of thebattery module.
 15. The battery module of claim 13, wherein the fluidflows through a first fluid flow segment in a first direction from afirst end of the heat exchanger to a second end of the heat exchangerand flows through an adjacent fluid flow segment in a second directiondifferent than the first direction.
 16. The battery module of claim 15,wherein the inlet is adjacent the first end of the heat exchanger andthe outlet is adjacent the second end of the heat exchanger.
 17. Thebattery module of claim 15, wherein the inlet and the outlet areadjacent the first end of the heat exchanger.
 18. A battery systemcomprising a plurality of battery modules, each battery modulecomprising: a plurality of electrochemical cells arranged in a first rowand a second row offset from the first row; and a heat exchangerconfigured to allow a fluid to flow therethrough, the heat exchangerdisposed between the first and second rows of cells and having a shapethat is complementary to the cells in the first and second rows of cellsso that an external surface of the heat exchanger contacts a portion ofeach of the plurality of electrochemical cells; and wherein the heatexchanger is configured to route the fluid between an inlet and anoutlet such that a path of the fluid flow includes a plurality ofadjacent fluid flow segments.
 19. The battery system of claim 18,wherein the battery system comprises a first layer of battery modulesarranged side-by-side and a second layer of battery modules arrangedside-by-side and provided above the first layer of battery modules. 20.The battery system of claim 18, further comprising a first manifoldprovided in fluid communication with each of the heat exchangers of theplurality of battery modules and a second manifold provided in fluidcommunication with each of the heat exchangers of the plurality ofbattery modules.